Laminating Poop Deck Topskin Over New Core

September 4, 2017

Getting back to Joule over the holiday weekend, I returned to the aft deck to laminate the topspin over the new coring.  I began by cleaning the cured thickened epoxy (squeeze out) from around the edges of the new core material, and then lightly sanded those surfaces.  After vacuuming the surface and solvent washing it, I covered with a thin layer of plastic to create pattern for the 1708 biaxial cloth.

I traced a larger outer layer onto the plastic, and then a smaller inner layer.

The larger pattern would be laid on first, and then the smaller inner layer.

I cut the patterns from the plastic sheeting, working with the larger outer layer first.  After cutting the larger layer, I cut the plastic pattern down to the smaller inner layer dimensions, and then cut those patterns from the 1708 biaxial cloth.

With all of the patterns prepared, I moved onto Joule to prepare the deck for lamination.

I wet out the new coring and then applied thickened epoxy (406 silica and 407 low-density) as a gap filler.  After this prep work, I moved onto my work station on the ground and began to wet out the first (larger) layer of cloth.  I laid the material down as I wet out each piece of cloth; and then proceeded in the same way for the second (smaller) layer.

With both layers on, I then covered the lamination with a clean layer of plastic and secured it to Joule.

I worked below to cover some fastener holes from the inside with tape - prepping for fill work.  Since I ran out of solvent, I decided to call it for the day.

Total Time Today:  3.25 hrs

Final Filler on the Starboard Rub Rail & Cockpit

August 30, 2017

Wanting to keep progressing on at least the starboard rub rail and cockpit, I went ahead and water-washed the previous epoxy application that was now cured.  After cleaning the fill areas along the rub rail and starboard side of the cockpit, I broke out the RO sander and 220-grit paper to clean things up.  

I noticed that a couple old fastener holes along the rub rail needed yet another fill, so I made note of them while proceeding on up into the cockpit to sand those areas requiring it.

The old fastener holes and bits of gelcoat that were torn off during removal of the cockpit trim (glued in with 3M 5200) were nearly there as well.  I noticed just a few areas that needed a bit more attention.  I have yet to begin filling the fastener holes on the port side of the cockpit, but am making good progress.

The large hole that was located on the aft portion of the starboard cockpit seat was just about fair as well.  This formerly large hole would require but a couple more rounds of sanding/filler, but was looking very nice indeed.

I solvent-washed the sanding residue from the work surfaces, and then mixed up a 1/2 ounce of neat epoxy to 'wet' the surfaces of the two fastener holes along the starboard rub rail needing just a bit more filler, as well as the large hole in the cockpit.

After wetting those surfaces out, I mixed another 1/2 ounce of epoxy and thickened it with 407 low-density.

I applied the filler with a squeegee on these three areas.

The last thing to do today was to cover the starboard rail with a rosin paper to protect the cured epoxy from UV damage.  I will keep these areas covered until I can get a first round of primer on.

Total Time Today:  .75 hrs

2nd Round Filler for Starboard Cockpit and Rub Rail

August 28, 2017

She was too tempting, staring me in the face as I arrived home from the office...I mean, if you could have seen her lines in the light of the afternoon glow!  I dared not waste another second with internal deliberations of whether it was right or wrong, if people would approve or not; I just couldn't resist, nor would I carry any guilt for my decision.  I quickly slipped into something more comfortable...grabbed a scouring pad, bucket of water, a towel, and made my way over to Joule's hull.  Gosh, what did you think I was talking about!?   

With the cured first round of filler, I needed to take the amine blush off the surface of the epoxy before I could sand and prep for an additional round of filler.  The amine is a waxy coating that cures on the surface of some epoxies, and needs to be removed prior to moving forward with additional work.  This effort was a quick scrub with the scouring pad and then a towel-off.  With the surface clean and dry, I applied a 220-grit pad (being fresh out of 120s) to the RO sander.  I knocked down the proud surfaces of the cured epoxy and exposed areas that needed a 2nd fill.   

I moved quickly along the starboard rub rail, and then into the cockpit...

...the prior thickened epoxy (West System 406 silica and 407 low-density) was easy to bring to a roughly fair surface.  After cleaning up the sanding tools, I applied a quick vacuum of the surface,  wiping down all areas to be worked again with solvent in order to remove any potential contaminates from the sanding process.

I mixed up a couple ounces of epoxy and then thickened it with 407 low-density filler.  I applied the thickened mixture with a squeegee for the 2nd round of filler.  It is likely that I will come back with West System's microlight filler for the final fairing effort, but I'll make that decision based upon how the hull looks after a good sanding with fine grit paper.  Cheers!

Total Time Today: .75 hrs