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…



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…



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)



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…



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!


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)


Layout for the rudder quadrant…

IMG_1153The ‘bricks’ made from 30 layers of fiberglass was cut into a 220×220 milimeter square and sanded down to a thickness of 25 milimeters. The layout for the rudder quadrant are drawed with a permanent marker, ready for the router…


24 layers and counting…

IMG_1152To be sure the rudder quadrant will be solid the layers of fiberglass are 24 with more to come! Six sheets of fiberglass are moulded with polyester resin in every step, hardened and washed down with acetone etc.


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…


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…)


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)


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…


Construction in progress…

IMG_1128The construction of plywood are in progress, the port plate are installed with thickened polyester resin and secured with stops of fiberglass. I had some left over and used the thickened polyester resin to fill in were the plywood was uneven or smooth. When sanded the plywood surface will look great…


Mainsheet traveller gone!?

IMG_1130Where did it go? The mainsheet traveller are removed and left the cockpit larger! I’ve been searching, reading and consulting, from this the mainsheet traveller are removed from the sailboat, not to come back – instead a mainsheet bridle system are installed in the future, this allow a more open cockpit and a simple system thats easy to maintain and repair on the sea…


Making ready…!

IMG_1112In order to make the plywood construction ready for installation underneath the cockpit, the parts are individually sanded and painted with polyester resin. The lists to support the construction are secured with strips of fiberglass, when hardened they are ready for epoxy paint and installation…

The stringers are painted with polyester resin, when hardened they will be glued to the hull with thickened polyester resin and secured with strips of fiberglass.


Forming the frame…

IMG_1113Underneath the cockpit bench I’ve added more strips of fiberglass to secure the frame of the hatch even more! With thickened polyester resin I have begun to form the frame into shape, this is a working progress – sanding – polyester – sanding – polyester – until the result is satisfying…


First step for wheel steering – again!?

IMG_1106A few weeks ago I formed the first step for the wheel steering from mahogany, this was ready to be mounted in the hull with fiberglass – however, I could’t find the specifications for the wire blocks? How strong? How much load from the wire?

To come up with a solution were I knew the exact specification of the wire blocks, I needed to construct a new ‘first’ step to the wheel steering! This was a better solution in many ways, easier to maintain and service, and easier to repair and chance spare parts! This is perfect, when doing things complicated – but simple!

Two pieces of mahogany formed to lead water between them to the bilge, glued to the hull with thickened polyester resin and secured with strips of fiberglass! Later comes the sanding…!?!

(In picture you can also see the stringers are secured with thickened polyester resin and fiberglass)


Arrival of Darth Vader!

IMG_1099The new mask just landed on the address! It’s a half face mask respirator with filters from Honeywell, this will protect my health in a proper way!

To save future shipping cost I ordered three A2 filters and four P3 (R) filters, this will grant me plenty of hours in the boat, working with the fiberglass, grinder and sander…

A2 filters protects from acid and gas, and the P3 filters protects from dust and particles in the highest level…


Stringers in action!

IMG_1097Yesterday I pre-mounted the stringers underneath the cockpit, made them ready for action today! With thickened polyester resin I ‘welded’ the stringers to the hull, sanded and secured them with wide strips of fiberglass…

In the workshop I’m working on the platform to the water tank and the section/wall between the compartments of holding tank and water tank.


Pre-mounted stringers…

IMG_1091To install the construction underneath the cockpit correct, the first three stringers are pre-mounted only with four strips of fiberglass each. This will hold the first stringers in place once hardend, allowing the main work with fiberglass to the stringers without problems…