82 aquasport osprey 19.6 rebuild

[gran398]

Thanks gman! Yep, getting excited...has been a lot of fun (and terrific diversion from the everyday mundane) planning things and sourcing stuff

Glad dirtwheels answered your flooring questions. Hopefully our master rebuilders are following your thread too. They shine on layup, glasswork....actually everything.

[dburr]

Instead of butt blocks you could cut scarph joints at 8:1 on the ends of the ply then glue together to have a seamless joint. A little more work but it is psycho strong and no butt blocks in the way..  You can stack the ply and cut both scarphs a at once with either a router mounted on a home built jig or you get a good workout with a 36 grit grinding pad followed by some quality time with a really sharp plane...

[gman 82 aquasport]

Going out on a limb here, scarph joint , would that be like putting a 45degree on both pieces and lapping them that way kind of like you would do on a deck board? I can go either way with the attachment, neither of them sound to difficult. :)

[dburr]

You are correct but the joint should be at least 8 times longer then the panel is thick, so a 3/4 inch piece of ply gets a 6 inch long "ramp" cut to a feather edge on the end.  That provides A HUGE glue surface and works really well.  I've used that method on panels for skiffs and kayaks and it works great.  More time but no hard spot in a bent pannel caused by a butt block.  Probably overkill for a deck the will have 3 layers of glass around it but a good scarph is really satisfying to make..  And isn't this all about one degree of overkill or another?     !

[gran398]

That is a terrific suggestion dburr.

gman, in order for the scarf to fit the foam....you could mark the foam and use a router. Shouldn't be too bad. Just a little messy

[dburr]

Routed some foam on a skiff build... Wish I had a nuclear powered super charged shop vac that @$&£€¥!! dust got everywhere and it was surpiseing what turned blue , even with a suit,hood, respirator and taped sleeves....  Man what a mess but it did a great job...

Just in case, here is a link to a page on scarph/scarf types, kind of cool.

http://www.oneoceankayaks.com/stitchglue/plyshophtm/scarfjig2.htm  

[gman 82 aquasport]

OK, got the floor panels cut this morning and fit them around lunchtime, decided to use butt block for its ease, also my floor used exactly 3 sheets 4x8 3/4 in from end to end with a 1 1/2 in cutoff at the stern, kept me from having to buy more plywood, scarph joint looks interesting if I ever rebuild another I will use it :)  ..First pic is from the stern
2 larger(8in) holes are where the fuel fill line connects and the one closer to the stern is the fuel feed and sending unit, both will be under the console.
The small one closer to the bow is over the vent hose(4in)
Pic from the bow
Small hole at stern is for bilge pump, it will be bigger , haven't decided if going 6-8 in round or 6x12 rectangular.
I will cut the hole for storage access next week right before glassing the floor in, it will probably be 13x27..
Wife says it 's starting to look like a boat again, if I could just get her to roll epoxy on  
 Will post a pic Saturday of the way I put the reccess at the stern for drains, lowered it in the center 3/4 inch.    
Thanks dburr for the link on how to set up a scarph cut I will save it for later

[gman 82 aquasport]

Took them out this PM and glassed the bottoms, so that Monday I can set them and screw them down :)
I see alot of PB in my near future

[gman 82 aquasport]

Got the floor pieces glassed on the bottoms(lesson learned, never try to carry a 4ft x 5.5 ft piece of ply with wet epoxy and glass on it to lay it on sawbucks, you will wind up with epoxy in your hair ) Installed them on Monday 3/5, glued and screwed, will post pics on Sat 3/10 after I get off duty..I am planning on glassing the topside Sat...1 layer 17oz, 1 or 2 layers 6 oz,laid opposite directions, 1 layer 4in tabbing and topped with a 8in layer tabbing glass around the perimeter..Before I lay the glass I am mixing PB to lay in the edge crack to get a build up to smooth with a spoon so the glass will roll up the wall edge (no 90 degree edge)good thing I have about 3 lbs of woodflour on hand Will post pics of the lay-up after I'm done Sat or Sunday, going to try to lay it up wet on wet, so no sanding between layers.

[gran398]

She's lookin' deluxe

Good job!

[dirtwheelsfl]

Sounds like youve got it under control. The bigger the radius the stronger it will be too. Ive got about 4 different size sticks just for doing fillets. I like to lay down the wider tab first so you have more contact surface, then do the narrower one. The second layer will strengthen the first one. Just a thought, makes me feel better anyway ya know... Even better would be tabbing and decking all in one piece, super strong.

[gman 82 aquasport]

Thanks gran, she's getting there..

dirtwheelsfl, thanks for the input about the tabbing, I hadn't decided which way to lay it, but larger first makes good sense. :) .. I'll lay the 8in first then go back over with the 4in.. My plan is to take the 17 oz and the 6 oz cloth all the way to the upturns on the sides, that way the floor has 4 layers at the edge. I will get as big a radius as possible with the PB. Not going to cut the storage area hole until glass has dried..that way
 I can place the seat in place and get the hole right where I want it.. Tommorrow will be a long day of mixing and rolling and brushing Wish me luck :pirat:

[dburr]

The fillets will go really fast if you put the goop in a folded up piece of plastic to make a disposable "pastry bag".  The folks at your local Win Dixie bake shop can show you how to fold it up, it can be described (make a 14x14 or bigger square of plastic then folld/wrap it up in a cone shape, staple rhe wide end to keep it from unwrapping) but is easier to see.  You load the bag, cut the end off the size you want and then have at it.  For big layups I have a bunch of "bags" stapled to a board waiting to be filled so I can keep the batches small to keep them from cooking off to soon.  It goes really slick. The spoon method is way to slow and will make you nuts..

[dirtwheelsfl]

Yuuuup

[gman 82 aquasport]

My pastry bag of choice is a gallon size ziplock with a corner cut off to size, used them to attach the pieces across the stern to hold the floor..Like you said the trick is not loading them up to much to get them to cook off to soon, that happened on the stern part, the bag got real warm real quick got my attention real quick to  :pirat: