Boat Refit: The Hardest Task Yet [E18]

#boatbuilding #boatrestoration #refit #sailboat #boat

In this episode we build the pilothouse roof. This was one of the more challenging tasks yet in this whole build.
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Previous episodes:

[kathrynaston]

To make the shapes, you make parallel cuts along the wood or foam, put glue into the cracks then form it over the dog house. Once you have the shape, then laminate it

[philkakid]

Brand name for colloidal silica is Cabosil.

[flyinggybe]

Good decision on the process and vacuum bagging one side first! A couple things to consider as you gain more experience vacuum bagging. If you leave a larger bag perimeter for the butyl tape, it's easier to avoid having some wet epoxy disrupt the bag seal. Also, this allows placing the suction cups for the vacuum hose outside the actual part to avoid sucking an undesirable mount of fiberglass and resin on the part under the suction cups. This also allows foregoing the suction cups and just using some extra layers of breather leading to the vacuum hose connection points to the bag perimeter. One of the nice things about vacuum bagging is that, as long as you have adequate resin saturation, you can spend much less time working out any air bubbles before sealing the bag since the vacuum takes care of that. This also saves some critical time in bagging large parts in warm conditions and giving the vacuum adequate time to do its thing before the resin starts to kick. One more thing, if you place the vacuum pump further away from the bag, and even behind a wall, it's much easier to hear any leaks as you work to quickly chase down any leaks and seal the bag. You can add some inexpensive vacuum guages around the bag perimeter to make sure you're drawing adequate and even vacuum around large parts. Again, glad to see you making a great choice in how to proceed with the project!

[susanmccarthy]

I am so excited to see all of the subscribers! The comments are getting very technical, which is wonderful, but my comprehension is limited. So let me just say, with no technical knowledge or sailing experience, I am still riveted. I admire Matt's tenacity, expert knowledge, and willingness to learn. And Janni is killing it as the videographer. I am proud to know you two. And I love to see the extended family members as well.

[JENewport]

Thank you for sharing the learning process. I would feel pretty exposed and you are taking on such a big project which would make it even more so to me. Keep it going!

[lindaperkins]

Great to see you and your dad working with you. Can’t wait to see it.

[svlamancha]

Great progress. That’s one big panel you must have been against the clock to get it all laid up and bagged in time. 👍

[Rubinho]

Just discovered your channel. A very interesting project on a boat I remember even if I was a bit young during this first Vendée Globe. Happy to see It still exists and in good hands. What an incredible work you realize. I will follow your project with pleasure and impatience. Greetings from France 🇫🇷!

[fransdriesen]

Just amazing what ideas and brainstorming can do.. I enjoyed the way you approached these seemingly challenges and for sure had your ears open for Janni's input..
Your relaxed and methodological way of resolving and executing these projects is just outstanding..I am not very familiar with fiberglass and related techniques and yes, I am learning a lot even at my age..
Thanks for sharing

[kayakninja]

This is a fantastic video. I'm so excited for you two, to get this critical piece in place!

[andreac.]

Big project, talent and team.

Chemicals are scary, I would always wear a mask.

[SalingSamantas]

I know you're already past this point but if I were going to do something like this I would have used v-groove or beaded tounge and groove bow to stern for the bottom layer. Maybe painted to lighten the interior I'd not natural wood or stained. Just and idea that Poped into my head as I was watching.

[DobDog]

Great progress for sure. Also I just read your article in Cruising World. Nice job on that, great to see more coverage of your project.

[robinhodgkinson]

Looking good. I think you’ll be pretty happy with this technique. It worked a treat for me, especially as you can fair it while it lays flat on the floor before flipping and fixing it down onto the cabin. If you find en masse the stiffness is too tough, you have a fallback which is to cut some shallow slots on the foam side to help it bend. But I’m thinking once you secure one side it will bend just fine especially if you clamp a 2x4 or similarly onto the opposite edge and then weigh/hold it down. The glassed side won’t let it break.
It’s interesting how you commented that once you glass one side it actually feels better to bend. That was exactly my experience. I fitted my whole cabin top like this, glassed the top side, then cut out my hatch from the roof and it retained the identical curve! I then edged both the hatch and cut out to create an overlap. Fits like a glove. Looking forward to following progress. Cheers

[yachticus]

Curious _ I think you might have done the vacuum bagging in situ on the roof - basically to get the foam to adopt the right curve. I guess if you can bend it when it is on the cabin top same effect. Have you looked at the VanDestadt design pages - some pretty clever ideas on shape / form

[leonply]

In all honesty, I would have raised the sides of the cabin/doghouse, in order to give a bit more headroom at the sides, and would give a flatter curve on the roof. The first time that you have to stand on the roof in rough seas, to look after the sails, a flatter roof would be much more appreciated.
All in all, a fantastic project and the finished boat is going to be gorgeous.

[luca_sbll]

You could build the spreaders yourself by laminating carbon fiber, but knowing of the potentially catastrophic consequences of something like that failing it's for sure something that has to be evaluated more carefully

[KandMe]

I tend to think that you need to laminate the topside of the foam differently and thicker than the bottom side.
A lot depends on the laminating and how much glass used and what type of glass. I mean epoxy or fiberglass or alternative.
This is if you are going to bend it later. How much glass compared to cloth is critical is what I am thinking.
Ideally you need to squeeze excess out rather than keep adding to get it right. I think laminating is a developed skill.
Just not so sure it is a good method to keep adding small amounts to get consistency just right.
Suggestion would be to dress the bottom a few thin coats before bending it to shape, then the top once roof is placed and shaped.

[clivestainlesssteelwomble]

Take a look at how they did it on
Parlay Revival or james at Sailing Tritaia.

[cjprimata]

Interesting let’s see what it comes from it, should be a cool boat perhaps avoid wood as a strategy.