new 222 rebuild

[JimCt]

My project is dragging a bit too but an hour here & there still pushes the effort forward.  Be interested in your steps in making the custom hatches.  Am considering making hatches for the 240 for additional access & stowage.  There's a lot of wasted space under the decks of these boats.

Keep the pictures coming... good education for me.

[Shine]

Shine- work looks good- I can't wait to see this one come togehter.

When you're done with the molds, are you going to use them for something, or would they be for sale?  I could use a few hatches like the middle one you're building... let me know please.

Richard, keep this secret  8)  :) ....

The 90 degree molds are made from plastic - In the fence department of home depot you will find the white plastic fence posts..... well just cut them  in half (lengthwise on the the angle), coat them with wax or PVA and you ready to make those brackets.

they are not perfectly square and they are not perfectly smooth on the inside, but for making a few parts that are going to be hidden anyway, its perfect.

I did make a mold for drain lips, and I did not like the way they came out so i will be making another mold soon.  That one will be a real mold as we plan on using it for a long time.

[Shine]

Be interested in your steps in making the custom hatches.  .

Jim,

The hatches are made from the cut out of the bulkhead.  The only thing that has to be made is the lip.  Also have to put in a latch.

[Shine]

coming in place.  It held true by dry wall screws, until we "tack weld" with epoxy.  Then a fillet, then glass it to the deck.  

The back side has been glassed already, so it gave the part some stiffness and allowed it to sit fair - a straight edge clamped also helped.

Its coming along now.  The only thing that has to be "made" now is the hatch drain channels.  I am unhappy with the first run of these, so we are going to make a mold for a better shape.

[LilRichard]

Very nice.  Can't wait to see this finished!

[wiler55]

what is that material that is wrapped around the cap what is it made out of? and what is a fillet? is it just thickened epoxy?

[John Jones]

and what is a fillet? is it just thickened epoxy?

http://bertram31.com/proj/tips/epoxy.htm

[JimCt]

Good article J.J.  Be perfect for the Resources section.

[RickK]

and what is a fillet? is it just thickened epoxy?

http://bertram31.com/proj/tips/epoxy.htm

Great article - I agree with Jim, can you add this link to the resource section please John?

[Shine]

coming glassed to deck, used a 1/2" radius fillet...






then we glassed it right after "wet on wet"...



yesterday we got the first of the fairing material on the boat.  This was a loose mix, more of a "slurry" not a thick paste.  We want it thin so it will be easy to fill the weave.  Subsequent fairings will be thicker.  We will move to Quick fair when the shape is close...

[JimCt]

Looking good!  What was the filler mix?  Just cabosil?  Did you add chopped glass to the mix?

[Shine]

Looking good!  What was the filler mix?  Just cabosil?  Did you add chopped glass to the mix?

Thanka!  I cant wait to get more fairing and some primer on.

For fairing, we use a blend of phenolic micro balloons, glass bubbles, and a little silica (cabosil)

100% cabosil (silica) - is way too hard to sand, so is wood flour , milled fibers, milled cotton, and chopped glass.  Thos fillers are best for structural applications.  You would end up using twice as much sand paper  

Our blend has about 5% silica by weight - just enough to keep it from sagging or running.

[JimCt]

Reason I ask is that I've had cracking problems with fillets just filled with cabosil.  Chopped glass seemed to help. After the fillets cure I over-coat with microballooned resin with about 10% cabosil for final fairing and an easier surface to sand.

[Shine]

Reason I ask is that I've had cracking problems with fillets just filled with cabosil.  Chopped glass seemed to help. After the fillets cure I over-coat with microballooned resin with about 10% cabosil for final fairing and an easier surface to sand.

I would not recommend ever making fillets from 100% silica - much too brittle, even when using a resin with a higher elongation (epoxy).

What resin do you use?  

For fillets, I use wood flour and a tiny amount of silica (wood flour is very fibrous and strong, so is milled cotton)

[JimCt]

Polyester.