Continued Surface Prep (Fill & Fair) and Creating Cockpit Seat Hatch Molds

October 14, 2017

I got to unpacking some recent arrivals to the shop - preparing for interior paint, including the bilge.  In addition to the paints that arrived, I also received some 1708 biaxial and some Divinycell for the cabin sole recore work to be completed.  Setting these items aside, I got to work on Joule by beginning with the usual water-washing of the previous fairing application.

After washing off the cure amine blush, I turned to addressing the imperfections across the surfaces of the cabin top and sides.  I dished out crack and gouges using a spiral saw, and then vacuumed up the debris. 

I solvent-washed all worked areas as preparation for an application of fairing compound (epoxy thickened with 406 silica and 407 low-density).

With the worked areas cleaned of contaminates, I applied a film of 'neat' epoxy - not thickened with any filler compounds - and then proceeded to mix another batch of epoxy this time thickened with the aforementioned recipe of thickening agents.  Since this mixture sands relatively easily, I went ahead and "slathered" on more material than I should in hopes of limiting myself to one application of filler, and two at the most.

I also skimmed a coat of fairing compound on the nearly complete poop deck and counter.

Next, I turned my attention to fabricating cockpit seat locker hatches - at least giving it a go!  Using the hot glue gun and scrap materials from the shop, I marked out what would become the interior dimension of the port and starboard cockpit locker hatches.

With both templates built, I removed them from the Joule and continued working them in the shop.

I used a 3/4" sheet of polystyrene to prepare the molds, for which fiberglass will be laid.  I cut out two pieces each for the port hatch and the starboard hatch, in oversized dimensions.  I then glued up the two pieces, creating a 1.5" thick mold.  Next, I scribed the lines of the templates onto the mold material, and then cut out the mold to match the dimensions of the port and starboard templates.

In a future work session, I will radius the top of the molds on all sides to prepare them to accept the fiberglass.  Once the glass is applied - probably 3 to 4 layers of 1708 biaxial - I will remove it from the mold and glass in support material on the underside of each hatch.   I expect the exercise in fabricating the hatches will run 6 to 8 hours of work with limited materials required.

Total Time Today: 3.75 hrs