1973 196 rebuild question

[Duffy1470]

Glassed other side, same schedule.

[Ulysses485]

Looks good Duffy! Are you going to use honeycomb board as the coring material? I am curious how your experience is with it as I don't have much experience with it, YET. Curious to hear your experience and thoughts. Thanks for sharing!!

[Duffy1470]

U, the honey comb is light, inexpensive, and glasses into super stiff, zero deflection panels.  Finishing the edges of this stuff is not something I have experience with, looks like a pain in the rear. Rick did a great looking, well documented job on his build, so it can be done. My strategy has been to terminate the ends in a major glass area, like deck to hull where no one will see the edges.

[Ulysses485]

I should have been more clear...I have 9- 4x8 - 1'' Panels of Honeycomb (scrimmed backing, no glass) that I will use for decking materials. I glassed up one large panel of it so far and glassed it into the hull for a fuel tank subfloor in my 240 project. I am curious how your experience will be using it in a mold application. I would like to use it that way to build hatches, hatch gutters etc. in a
 melamine mold.  Not sure how to do it other than laying up the panels first with at least one layer of 1708 and sanding them down before setting them into the mold with some kind of thickened resin, putty compound, or 1.5oz chop strand mat.

[Duffy1470]

I already laid the deck down on the melamine.  I trimmed it up today and will be glassing/bonding the honeycomb to it this week. I plan on putting a layer of 1708 or 2 over that. I can't answer your question yet but it should be soon.

[Duffy1470]

U, I lied about coring with honeycomb. I forgot about this piece from a few weeks back. The comb cores great. The pics are of the shelf I added inside the console anD the comb will receive the end of an umbrella. My skills are limited, however this piece came out great so the product, comb, is easy to work with. Used a combo of matte and 1708.



Yes, the shelf is actually the front small hatch off the casting deck


Other work on coring the front deck
Layer of matte, then add comb


Weighted down


Also fixed vent hole in port hull side. Put packing tape on aluminum..... see pics

[Duffy1470]

Other side of hole patch



Glassed underside of front deck. Will start fitting it tomorrow.

[Duffy1470]

Deck came out good I think. Need to clean it up. Rick planted the deck rail idea in my head so I will do that next.

[RickK]

You don't have to have a rail if it fits tight and you can cover the glass work to the hull. That was what I was thinking when I mentioned the rail. You can glue the deck to the rail and fill the gap along the edge with thickened resin putty. If you have the liner to cover the joint, no problem.

[Duffy1470]

I put some hard points in for the deck to rest on.  Three on each side. I think you were right to suggest them. I am starting to lose my zeal for the project, so any time you see me cutting corners, please call me out.

[Duffy1470]

U, finished the deck with the comb as core. Do you have any questions? I am more than happy to answer anything you have.

[McAllgeyver]

Looking great. That deck came out nice. If you can reach under deck and get some glass connecting hill and underside of deck it would be beneficial. That bow takes some beating. Glad you enlargerd the gutters which gives the hatch room to be thicker and stronger.
You’re in it now. Don’t lose steam. Classic Aquasport will get you to the end. And then some. Would unequivocally have not finished my boat if it was not for the few main guys here on CA. I owe them more than they know and will be forever indebted to them and CA. 

[Duffy1470]

Roger that mcall on all points. I'm going to finish, but definitely plan on cheating at the end by having someone else paint it.  If it looks like a 52 year old boat and my wife bitches it can be someone else's fault.

I don't know how I could glass from the underside.  I am open to suggestions.  Was planning on lots of gorilla glue construction adhesive ultimate. I could easily be talked into 5200. I have to order it online which is why I end up using the gorilla glue product.

I am definitely scared/reluctant/dreadful to glue and glass the deck down. That's it. Game over. If it's not in there, too bad. So, I will do as many other topside items first.

[Ulysses485]

Duffy, project is looking good and coming along nicely. I was just curious about the laminate schedule for bedding the core. Did you laminate the side you bedded in the mold?

Do you have access to those three hard spots underneath the front deck or are those areas outside of the fish box and basically dead space? A good practice it seems common is to tie everything together with structural tabbing glass so its basically all one part. I believe the hull to deck joints should be glassed in.. in lieu of just 5200 or thickened resin. I know you spent all this effort on a smooth casting deck so I would get some Peel Ply and lay that on the structural ties so fairing isn't so bad.

[Duffy1470]

The laminate schedule from top to bottom is:
-matte
-1708 (matte side to above matte side)
-matte
-honeycomb
-Matte
-1708
I am definitely tabbing the deck in from the top  but not the bottom (cant get to the dead space outside the fishbox/storage area to glass from bottom).  The area of concern is the outside edge of the deck. The honeycomb is left exposed. If it were going to delaminate, I suspect it would be here. The bottom is supported by the hard points and will be glued and the top will be tabbed with two layers 1708 and layer of matte. I think it will be good.