Friday, December 30, 2005

Bulkheads and mast step:

December 1
Well, records are a little shaky, but during the last couple months we have made a fair bit of progress.

The bulkheads in place when we took possession of the boat were made of low quality half-inch plywood and painted with some kind of yucky sticky white paint. They were glassed in very poorly too. No fillets were under the glass where it goes from bulkhead to hull. Since the bulkheads hold the chainplates, and thus, keep the mast from coming down, we decided to replace them.

Originally there was an oak stringer glassed into the core of the cabin top, parallel with the bulkheads, which served as a step for the mast. When the bulkheads were replaced last time, whoever did it cut away most of the glass holding in the mast step. Then they attached the bulkheads to it with a screw (one!) on each side, and a single layer of 6oz fiberglass cloth.

When we got a chisel under the edge of the glass, which was ostensibly holding in the bulkheads, we could peel it up like masking tape. A couple of swift kicks and the old bulkheads were history. The old mast step was a little more robust, so Corey attacked it with a mallet and a chisel.

Then began several hours of grinding with a monster 7” Milwaukee disc grinder and 36-grit sandpaper to prepare for new bulkheads and mast step.

Here is a shot of the new bulkheads, and mast step fitted, but not yet glued in. The brace in the middle is temporary...

We settled on a 3/4-inch plywood, nine ply plus mahogany veneer, for the new bulkheads. Corey found a piece of mahogany to use for the new mast step. The new mast step is three inches thick (fore/aft) by almost five inches deep under the mast, tapering out to just under three at the windows. It is slotted to receive the bulkheads.

Here is a side view showing how the bulkhead is slotted into the mast step.

Our resin and fiberglass arrived a couple days ago. While we were in France Bruce Schwab exposed us to MAS epoxies and after talking with Joel Mill of Devlin boatbuilding up at the wooden boat show in Port Townsend, we decided to go with it. Joel runs a website called boatbuilder.org where he sells MAS products at a significant discount, and has posted lots of advice about using it. The glass came from Fiberglass Supply in Bingen, Washington. Corey saw an ad for them in the back of Good Old Boat magazine, in addition to stumbling across them online. They were easy to deal with over the phone and are only one day away by UPS Ground.

We also got our keel back a couple days ago. We could have sandblasted it here, but it would have been a lot of work, so we took it to a place in Centralia. While it was there, we had them powdercoat it. It still needs quite a bit of filling and fairing before it can be reglassed because the casting is quite rough. Epoxy should stick to the powdercoat alright, the powdercoat provides an extra layer of corrosion protection for the steel keel, and it also means that we didn’t have to immediately epoxy it when we got it back from sandblasting.

Corey was sick for a few days so he sat down and spent some quality time with Skene’s Elements of Yacht Design and calculated the loads on the standing rigging to see what size wire we will need to use for the shrouds and stays. Maybe he’ll post the calculations later, maybe not. The shrouds and stays will be 5/32” stainless wire, which gives a safety factor of 2.8.

He also decided to make new chainplates because all the holes are oversize in the old ones. The new ones will be held to the bulkheads with five 5/16 bolts, which provides for about 200 pounds more strength than the shrouds.

20 Comments:

Anonymous Anonymous said...

glad to see another C22 re-fit in progress. please visit my site
www.johnvining.com click on the project boat. I have yet to deal with the keel and will need to drop and re-bed. good luck with the completion

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we have dropped our keel and are faring and rebedding it as well. photos and update soon to come...

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