PVC tube…

IMG_1436Before sealing all the compartments in the benches, the layout for the 12v system and fuel line are made. The simpel construction of PVC tube and fittings are set for the fuel line in port side and the 12v system in starboard side. This will clear out the cockpit for cables and hoses, with a clean and nice look…

(all fittings/connections are sealed with polyester resin)

[Day#697]

Coming together!

IMG_1428Today I cut the top plywood for both benches, the interior slowly comes together and it looks pretty good! The construction are just waiting for polyester resin and fiberglass, then sanding and painting…

[Day#696]

Room for battery!

IMG_1422To add modern navigation equipment the old fiberglass boat need a 12v battery bank. This box are placed near the bow to equal the weight aboard. The battery box are made from a simpel plywood construction but will be sealed with polyester resin and fiberglass.

[Day#692]

Benches…

IMG_1419To add safety in the old fiberglass boat i’m building to benches, reaching from the stern and all the way to the bow. These long benches are constructed with waterproof/airtight compartments, making the boat unable to sink!

The construction are made from plywood, sealed with polyester resin.

[Day#692]

Small foredeck

IMG_1414The small fiberglass boat are resting in my shipyard and the rebuilding has begun in it’s construction fase. To add something new i’m building a small foredeck on the bow with planning to mount a smooth cleat…

The blade on the circular saw are set leaving just a few milimeters in the plywood, making it posible to bend in a beautiful shape. Thickend polyester resin are filled in to fix the shape when hardend…

[Day#690]

First layer of fiberglass…

IMG_1405Grinded, sanded, washed and finally ready for the first layer of fiberglass! It’s a long proces to safe this small boat and if not it had history in the family, it should have been cut up and trashed. My grandfather bought this boat back in 1964, were it was a platform for lots of activity and fun on the water for my father and his friends. The boat ‘Tulle‘ had it’s first major rebuild in 1995, by my father and was brougth back to life again. Then it became the platform our family and now it will become the boat for my family after her rebuild…

By princip! She floats!

[Day#685]

Rebuilding the small boat

IMG_1397It’s a huge job restoring this old crashed small boat, several broken parts in the fiberglass and many holes! The boat was smashed on a rough stone beach in a strong storm, then forgotten for fifteen years in the reed…

Now the sanding and new construction (to add safety and comfort) has begun! With much fiberglass work to come…

[Day#683]

Arrival of a small boat!

IMG_1375Today a good friend and me drove to pick up the small boat, this was a journey not to forget! Long time forgot in a forrest of reed, the boat has been sleeping in fifteens years!? We took it down, just to drag it over a heavy stone beach and then climbing a very steep hill together with the fiberglass boat… this took more than four hours of heavy and exhausting work with lifting, pulling, pushing and maneuvering the manual chain lever block.

What a day!

Now the small boat is resting in it’s new home, in my workshop…

 

[Day#679]

Boat trailer…

IMG_1372A small boat in fiberglass has been given to me! The small boat isn’t ready for floating yet, but will once it’s landing in my workshop. To be ready for the transportation I searched the internet for used trailers, but with no results! However a brand new trailer cost almost the same as a brand new trailer in Denmark?!? So today I picked my new boat trailer up by the dealer and drove it back home, ready for transportation…

 

[Day#678]

Roller furler system…

Wagners Shipman 28 was up for installation of a brand new roller furler from Selden, this installation was made to replace the old and tired roller furler from Plastimo. The plan was to trash the old system, but I took it back home to my workshop, maybe to fix it up and save the ridiculous many money a new roller furler system cost!

Big thanks to Wagner!

(Plastimo 809-S)

 

[Day#669]

Man vs. Machine!

IMG_11990 – 1 !!!

Crawling in the small lazarette below the transom, working with the grinder and power file, was and are an ongoing battle between man and machine! For now, the machine won and I’ve been out for a couple of weeks due to my injury – the world famous Tennis Elbow!

If not in the boat, below the deck – I’m continuing the everlasting research in thoughts and solutions for the DIY project. However, this is also a pleasent break from the un-pleasent epoxy and fiberglass dust…

[Day#646]

Purgatory!!?

IMG_1172Below the transom and the stern platform with rising temperature, grinding and sanding the old epoxy paint and fiberglass hull, in the very small compartment – must be the sailors Purgatory on the hard!?

Is this necessary? No! Why do it?

I imagine to keep the cost as low as possible when building the sailboat back in 1971, the look and appearance below deck wasn’t important due to the extra expenses. The hull below the stern platform was rough but painted and the fiberglass material gave the surface an uneven appearance from not being sanded down properly from the shipyard. My goal is to minimize the forward and future maintenance on the sailboat, this also means cleaning and washing down! The rough surface on the hull below deck did hold up a great deal of dirt and water, but by grinding and sanding the surface into a smooth appearance the cleaning will come easy and the water will also run with ease to the bilge below!

[Day#630]

Router vs. rudder quadrant!

IMG_1159The plate from high density polyester resin and multiple layers of fiberglass, are cut in shape with the handheld router from Bosch. The router bits with tungsten carbide tips did the job perfect…!

On the picture you can also see the model, constructed to find the right diameter of the rudder quadrant and the axis in the pedestal. The quadrant/rudder will have 80 degrees travel and 540 degrees rotation on the wheel steering (same as the Bavaria 36) so when the rudder is amidships, it can turn 270 degrees port- or starboard to reach the stop (3/4 of a full rotation)

[Day#626]

Rudder axis ready…

In order to install the (future) rudder quadrant the rudder axis needs to be exposed! With the power file the fiberglass are sanded down in a 10 centimeter section in top of the rudder axis – just below the deck. To protect the axis it is safely hidden in a heavy tube of steel, this was cut away with the grinder in the same 10 centimeter section. The rudder axis are now fully exposed and ready for installation of the homemade rudder quadrant…

[Day#621]

Rudder quadrant !?

IMG_1141I’ve search out the internet for solutions for an rudder quadrant! I’ve made technical drawings, asked clever people with skills in metal work and it all comes out to very expensive cost!? The rudder axis only have a diameter of 25 millimeters, this needs special work…! To keep the cost low I’ve begun to produce the rudder quadrant myself from polyester resin and endless layers of fiberglass…

(I’m making two, one as spare part…)

[Day#620]

Next step to the wheel steering!

IMG_1142The steps for the wire bloks for the wheel steering are made and installed. Like the first step, they are made from mahogany and pre-drilled to mount the pad eyes. Look closely and you’ll see the mahogany steps are not the same height, this is made to let the two wires cross over eight other underneath the cockpit.

(Installed with thickened polyester resin)

[Day#620]

Cut away…!

IMG_1134The wire system for the wheel steering system was chanced for better and this needed more space the the wires to run by. In order to let the wires run underneath the aft cockpit, behind the pedestal weld (?) a new cut was necessary! With a wide selection of power tools I made great acces for the wires and builded a small box to install with thickened polyester resin and fiberglass…

[Day#616]