Saturday, September 5, 2015

August Work

August has been a lot of this and that. I am waiting to get the hull sprayed and since I took apart my stairs up to the boat it is rather awkward getting up and down. So in the mean time I am making good use of the time by working mostly on the shop floor and painting and varnishing up on the boat.

 I took the hull painting as far as I could.  The hull is prepped and ready for spraying, the bulwarks have four coats and the transom 8 coats of varnish. A few more would not hurt if I have time. The boomkin is painted with three coats of white Brightside. I was very particular about the boomkin. Way back I spent quite some time trying to find a good piece of Douglas fir. I wanted a heavy piece with tight grain at 45 degrees so all sides would be edge grain. Where it lands on the deck was then glued onto 1" teak so it would not be fir sitting on the deck. It was coated with S1 penetrating epoxy and then two coats of primer and three coats of top coat. I epoxy coated all the bolt holes before bedding on the boomkin/anchor roller and to the deck. The holes in the deck got countersunk so there would be a "donut" of goop around the hole. A general practice I have done with every hole in the deck.

Removed all the portlights after marking out the length of the bolts. Also filed a bevel in the portlight opening so I can put a good bead of goop around the spigot before the trim ring goes on. Now getting coats of varnish on the cabin. It's a big cabin and coaming so it takes time to go around it. The varnish and painting on the scuttle is almost done. So trying to juggle painting and varnishing with making dust.

I have had to abandon the Epifanes varnish I have always used and like. I tried every way I could think of but it seemed to skin over as soon as I opened a can but the final straw was I could source the Interlux Schooner varnish for half the price of the Epifanes. So Interlux it is for now. However, I can tell by the noxious smell that the interlux is not natural and it is thinner than the Epifanes.

Once the last coat was on the bulwark and sheer strake I was able to finally install the 3/4" brass rubbing strip on the rub rail. The channel for the chainplates is proud so I had to bend the rubbing strip there. I was lucky as my friend is a high school metal work teacher and I went with him so I could use his oxy-acetylene torch to heat up the brass and bend it around a form I made. I should have tacked some sheet metal over the form as the radius of the form got a little bigger each time I bend the hot brass over it and it started to burn it's way into the wood. It was little enough that it really did not matter. Trying to bend it cold would result in the brass work hardening, becoming brittle and probably cracking.

Milled up a big pile of hull ceiling and bulkhead staving. Also made the dovetailed drawers. I decided I had to dovetail them as it would be disappointing to open them and see a drawer screwed together or made of plywood. I got some really beautiful Western White Pine. Totally clear tight vertical grain and wonderfully easy to dovetail. Used 6mm mahogany ply for the drawer bottoms as it seemed to make sense for the application. The drawers also have raised finger holes and will have a simple turn button to retain them. I find wedges frustrating and am never confident in them to keep the drawer closed. I also wanted to avoid the unsightly gap at the top of the drawer you need when you have a wedge you need to lift the drawer to clear.

Making all the doors right now but forgot to take photos. Here is the settee backs though. Simple enough and just a bead detail to keep with the theme and a raised finger hole.

Also got the patterns made for the chainplates and backing plates for chainplates and windlass. Still need to do some more castings but getting the chainplates done was a big priority for being able to finish off the interior. The patterns are a split pattern and were rammed up vertically. So a little bit of taper to grind but over such a small area it is not much at all. Everdur Silicon bronze like all the rest of the hardware and nicely cast by Achinback Foundry just 20 minutes away in Langford. Sure am lucky to have a good foundry so close by. It is such a cool process where you send in some wood patterns and get bronze pieces back.

I was trying to figure out what the boot strip and painted bulwark and sheer strake would look like. The whole idea was to make the boat look lower, keep with the work boat heritage and cover up the 'glass work I had to do at the deck hull joint. I got out some old school pencil crayons and did some colouring...

I had to finish a cabinet in Cherry and Douglas fir. It was to be a filing cabinet so that dictated the size of the drawers and how many. I do not like mechanical drawer slides but in this case it made sense. The cabinet it frame and panel and the drawer fronts are thick douglas fir bandsawn veneer over Baltic Birch ply. The pulls are hand carved Paduk.

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.