Friday, July 24, 2015

Bottom paint

Finished the barrier coats on the hull. After sanding the hull with 80 grit with 6" RO sanders we wiped down and rolled the layers of Interlux Inter-Protect 2000E . We rolled 4 inches above the waterline as the boot stripe will be 2 inches above the waterline so the InterProtect will over lap 2 inches into the boot stripe. We re-marked the waterline using flexible clear PVC  tubing and water  with blue dye. It was a quick process for one of us to be at the transom at the waterline mark and watch the dye and call up or down to the other until the dye was at the mark. Worked our way around the hull and took probably no more than 20min per side.

I had thought about using the Interlux two part Perfection paint for the free-board but I found out that it recently has been discontinued in Canada so that left Awlgrip. I had favoured the Protection as it was easily maintainable by the user and while Awlgrip is one tough paint it is not maintainable and very expensive. Well, once all the reducers and converters etc. are available in early August we can spray the free-board. In the mean time I un-masked the bulwark and am sanding it down to give it a third coat of Kingston Grey Brightside paint and then put on the half oval brass rubbing strip onto the rub rail. I will also get to work on the chain plate casting patterns and start milling up some more hull ceiling and bulkhead staving for the interior.

Masked off and Inter-Protect 2000E rolled on hull. With the metal stands and my old lumber boat stand gone one can really see the shape of the hull.

Friday, July 17, 2015

Back to Work on the Falmouth Cutter

Will the blog live doctor?...Yes, I think I hear a slight heart beat...there is hope...

Last time I posted here I had written there would be a long pause. Long indeed. This past week I finally got back to work on the Falmouth Cutter. A lot has happened since I was last working on the boat and it felt a bit strange and also good to be back on the boat. I spent over three years in Sweden and completed my Journeyman's (Gesäll) exam at the Carl Malmsten school on Öland and worked for a small cabinet shop on the same island. I learned a lot and spent the three years refining my skills in furniture and cabinet making. I have to say that building my Gesäll exam Cabinet was probably one of the hardest pieces of woodworking I have done. One of the nice things about woodworking is one never stops learning and there are always new challenges to test your skills. Some of the work I did can be seen at this link:

It was a bit of a culture shock to be back in Canada and that was best dealt with by going on a month and a half road trip with the trusty 1989 Toyota Land Cruiser camping and hiking and canoeing around British Columbia and the Rocky Mountains of Alberta. After that it was busy with settling into life here and cabinet work. I also had to re-new my teaching licence and spent a semester teaching woodwork at a high school.

My plan this summer and fall is to complete the woodworking on the boat. Most of the work is interior work but I also need to make casting patterns for the chainplates and other hardware. The first thing that needed to be done was to paint the hull. Bryan from Channel Cutter Yachts who builds the FC34 came down this week to help get the hull ready. I had cleaned up the boat shed and the years of accumulated stuff under the boat as well as torn down the high scaffolding which I do not need any more and would be in the way of painting. I built new lower scaffolding and we sanded down the hull with 6" random orbital sanders. Next week we will mark out the waterline and paint the barrier coats below the water line. My friend who did all the coating work when I worked at Waterline Yachts will spray the freeboard.

I did a complete cleaning of the boat before covering it all up in preparation for painting. It was the first time I had seen all the cardboard off the deck and the whole boat clean in a long time. I thought I would post a few pictures. Next posting will be the painted hull.

First time I could look at the hull with out the scaffolding in the way for many years

Bryan busy sanding under the waterline

Boat is masked off and sanded ready for painting

Monday, April 9, 2012

There will be a long pause in work on the boat while I work with cabinet making in Sweden for two years. Will then return and finish off the last stages of the boat and finally see her afloat. It has have come a long way and yet there is still quite a list of things to do. Rudder, spars and rig, painting, motor installation, tankage, and plumbing, last parts of the interior, sewing cushions , sails etc. By now I have spent about 6500 hours working on on her. I anticipate another 1500 or so. So by the time she is done it will have been four years of work spread out part time over ten years. It's a big project and working by myself and part-time it will take time.

Sunday, August 7, 2011

A few pictures of the Kingston Grey used to paint the Bulwark and rubrail. When the hull gets painted the boot stripe will also be the same grey and it will follow the sheer.

The Boomkin and Boom Gallows painted

Various pictures

In the last week I got going on the long neglected forward cabin. The sitz tub is installed, cleated in and resting on some sturdy black walnut slats. The mahogany framed opening below the sitz tub allows for ventilation and access to the drain hose and it's inline valve for draining. Room for some light storage as well. The tub will be drained into a bucket and the grey water can be thrown overboard or down the sink. The cedar tub will be trimmed with bare teak and the lids for the storage bin ahead of the tub and the access to the anchor chain bins are also bare teak for simplicity.

Looking into the storage bin ahead of the sitz tub. Fiddles etc for retaining the tool boxes are yet to come. Yellow cedar hull ceiling and red cedar shelves. The shelves will hold the three plastic tool boxes and a canvas rigging bag. The 3 gallon fertiliser sprayer will provide the pressurised water for "showering" in the sitz tub. More room in the bottom of the bin for storage. I'll sew up some curtains for around the tub to help contain water when "showering". A bare teak hinged lid will cover this bin.

I won't be getting anymore work done on the boat for the fall and winter.   

Wednesday, July 6, 2011

Cabin molding

This job kind of deserves it's own post since the cabin molding or eyebrow is rather time consuming and is the last woodworking job on the exterior other than the rudder and tiller. I'll add more pictures as the molding gets finished in the coming days...

Here is fitting the corner pieces. They are the first step and rather fussy as the cabin ends curve around the corner to the sides but not on a vertical plane as the cabin sides have 3 degrees ( I think)  of tumble home. The fit was further complicated by the fact that my glassing job left the corners ever so slightly rounded...that is not perfectly flat...sigh...I'm not much for glass work 

Once the fussy step of fitting to the corner is done then I can saw out the rest of the shape...

Then shape it to the pencil lines on the sander. (This simple sander was a college group project and has served me very well for years now)

Here the corner piece is finished except for final shaping. Three more to go...

Fitting the pieces in between the corners now. Once fit shaping can take place.

Fitting the cabin front molding.

Shaped and fit to the corners. Once all the sides are fit the corners will get shaped and blended it.

All the pieces are dry fit here and ready for final shaping and then gluing. The shaping is mainly done with round-over router bits but then the rest of the shaping has to be done with block planes and spokeshave and sandpaper to get a nice round shape. In order to avoid chip-out I start with a 3/8" round-over (r/o) and then 1/2" r/o and finally 3/4" r/o. That leaves a nice round radius and only a slight flat spot that gets sanded out. The corners are done entirely with rasp, file and sandpaper.

Yesterday I finally received the bronze carriage bolts that were caught up in the Canadian Postal Strike so I can install the boomkin and gallows permanently.

The cabin molding got glued on after masking it off and also with some plastic around the cabin to avoid 3M5200 from potentially getting on the teak cabin sides.. The joints at the corners are glued with epoxy: When I do this I drill some very shallow small holes with a tapered bit into the end grain of each joining piece. I figure the thickened epoxy can key into the mating holes that way. All in all I think it went well. The molding is waiting for an evening of sanding.