Project - Aquasport 246CCP, 1979, Captain Koz II

[kaptainkoz]

Crowing moment…. The floor boards are permanently in! I am very pleased and relieved. It came out as expected with no negative surprises.  Definitely a massive undertaking for never have done this before but as always I give credit to this site for showing me the way. I would not have tried it without!

[RickK]

Coming along nicely Koz 

[kaptainkoz]

  thank you. I am elated! 

[kaptainkoz]

So I got to (over) thinking about the gas tank tub and what forces will be on it. The gas tank tub and cover will hold the captains seat (jockey seat), flip back cooler seat the gas tank and  a support for the roof of the pilot house. I have my concerns about the tub being mounted 360 degrees by a a 2 inch strip of peanut butter. So I decided to pad out the upper walls a bit so the tub fits tighter and later sending stainless screws through the tub, through the pads and into the stringers to help make sure everything stays put. Basically plywood spacers to fill the void between the tub and the stringer.

Gas tank tub is installed. The point of no return as far as any underfloor access. After many test fits to make adjustments it snugly fits in. I tacked the edges down with drywall screws to help lessen high spots. I will remove the screws and fair with peanut butter, then I will sink about 5 screws a side as mentioned above.





Next step is to prepare full floor templates for 3 layers of 1708

[kaptainkoz]

Floor template
I saved all the plastic sheeting templates I made for the plywood and laid them on the floor. I taped them all together into one sheet. I disregarded all the black sharpie markings and used a red, green and purple sharpie to mark the exact shape of each of the 3 layers of 1708 I plan on installing. I drew in where the center console and the coffin box will be. I plan on hiding all 3 seams under the width of the coffin box for minimal fairing. The seam for first layer (purple) will be 8 inches off center to the port side. The seam for the second layer (green) will be 8” to starboard of center and the final layer (red) will be centerline. You may have to zoom in to see the markings. I will lay two widths side by side, 20 feet long of 1708 on plastic on my garage floor and transfer the pattern. I will use the corresponding color marker so I can tell which layer is which.
I realize looking at the photos that the different colors didn’t photograph well but they are distinct on the real patterns.



[img width= height=]https://classicaquasport.com/ygallery/data/24/24427-8406-IMG1043.jpeg[/img]

[kaptainkoz]

Patterns
Spent a day or two cleaning out the garage. Yes… that is the same garage in the prior photos. I did a major clean up and added a shelf along the front wall to squirrel more stuff away.
Anyway I laid plastic sheeting down and pulled two 20 foot pieces of 1708 side by side and laid the plastic template over it. I am working last layer to first layer so this is the “red” final layer. All that means is that the seem is exactly down the middle. Kinda gave me anxiety over how much waste there is but I am telling myself I will use it elsewhere. After very carefully straightening out and positioning all the materials I used a red sharpie to traced the red markings from the plastic onto the glass, cut it and rolled it up on a cardboard fabric roll.









I then took scissors and trimmed the plastic sheeting template down to the “green” mid layer pattern so all the “red” sized template was removed. I then laid it down, traced it, cut it and rolled it. My old broken body is hurting! The green template has the seam line 8” of the two sheets of glass off center as to stagger the seam. 
Tomorrow I will cut the last “purple” template and prep the floor for installation. The purple layers seam is 8” off center the opposite side of green.

[kaptainkoz]

First layer floor
Passed another milestone today…. I laid the first layer of 1708 onto the floor. First I prepped the floor by giving it a light sand and paying particular attention to any bumps or high spots that were left from any of the peanut butter filleting I was doing. Then the floor got an acetone wipe down. Then I transferred the first layer from the plastic sheeting onto the floor using the “tablecloth trick” of giving the plastic a quick tug to slide it from underneath the 1708. I used a sweeping broom along the same 45 degree direction as the 1708 and smoothed it out to where I was satisfied with its position. This layer was critical as it only met or barely overlaid the existing floor items. The next two layers will cover more but this one was the filler or transition piece from all the existing items to the new glass. I used a paint roller and a roller pan at first but it was going too slow so I resorted to pouring the resin right out of the mixing tub onto the glass and then spreading it with the roller. This worked out much faster. I used a paint roller to spread the resin and get it all even then a fiberglass roller to work out all the air and work the glass flat. I made an “island” over the gas tank tub which definitely helped as well as plastic covered the hatches and taping over what was not to be glassed. I am very happy with the results and super relieved. I have been stressing this operation for over 10 years. Now. Glad it went well but I have two more layers to go. Its a very cool night at about 45 degrees but mid 60’s tomorrow so I’m counting on a slow kick to help settle any bubbles even more. I used 7 liters of resin.

[RickK]

  nice job Koz

[kaptainkoz]

Thank you Rick. It’s an amazing experience to be completing these levels of the restoration . I have never laid this large of a piece of glass at one time before. Definitely gratifying to have successfully applied this layer.

[kaptainkoz]

Second layer is down. No surprises. It went well. Poured right from the tub and used a 3” mini roller and an 8” paint roller. Then chased the bubbles with a fiberglass roller. Worked much neater and methodical than the first go around. Lessons learned. 7 1/2 liters of resin.
Probably Tuesday night for the last layer. Weather is 60’s during the day and mid 40’s for a low.

[kaptainkoz]

3rd and final 1708 floor layer is in the books. Once again very pleased. Definitely surreal to have passed this milestone after all this time. I know I keep repeating myself on that fact but the journey to get this boat done has been really rewarding.
I have to make some gel coat repairs along the bottom of the gunwale which was bad factory casting of hollows behind the gel coat in the mold. I’m going to mix some Cabo and gelcoat to patch the small voids then I’m going to mask it off and shoot the entire floor and a few inches up the gunwale.