Saturday, December 15, 2018

Alcort Super Sailfish ZSA ZSA 15 Dec 18 Toe Rail and Rub Rail Epoxy

15 Dec 18:

Released the rails, refastened the toe rail and rub rail with thickened epoxy. Screws to hold them to shape until epoxy dries. The thicker epoxy fills gaps and ensures a better bond between pieces. This product is good for use below the waterline, where ZSA ZSA's rail will spend a lot of time, it can be drilled, shaped, sanded and painted. It is also flexible, not as rigid as straight epoxy, so it will move with the wood a bit. We chose Jamestown Distributors TotalBoat THIXO because it mixes in the mixing tube, no guessing on how much filler to add to straight epoxy. It is also faster to mix up and use, but the cost is more per drop than resin/hardener/filler. Pettit makes FLEXPOXY, we used it a lot and like it, but it runs several dollar more per tube.

Epoxy for the deck edge seam, rub rail and toe rail.

As the pieces were pulled together with screws we looked for epoxy to barely squeeze out, which indicates that the joint is full. That is all the pressure that epoxy needs to bond, it does not need high pressure like glue, in fact too much pressure can squeeze the epoxy out of the joint. After the piece is attached we use a paint stick to remove larger bits of squeeze out, then slide a gloved finger along the perpendicular seam to make a curved fillet. This fillet helps shed water away from the joint. Be careful running rags or paper towels along seams as that can dredge the epoxy out of the seam. Another tip is to check the seam after it dries, sometimes the wood soaks the epoxy into the joint and it might be desired to apply another small bead of product. Here is a seam after we radiused the joint.

Coated the inside of the mast trunk and daggerboard trunk with epoxy.

3 tubes of THIXO for the seam, mast step and daggerboard trunk.

Alcort wooden collection, (L-R) 1950s Super Sailfish, 1965 Sunfish, 1950s Standard Sailfish.

Log of ZSA ZSA.

Friday, December 14, 2018

Alcort Super Sailfish ZSA ZSA 14 Dec 18 Dry Fit Toe Rail and Rub Rail

14 Dec 18:

Christmas Train!

Ripped the trim down to 3/4 inches wide to make the toe rail. It will cover the rub rail and deck seam.

Attached the rub rail first, then fit the toe rail. Left a few drain slots on the stern. Trimmed to length with the Japanese pull saw. Shaped with the Shinto rasp and 220 grit sandpaper. Temp fastened with small screws.

Eased the rails up a bit on the stern and bow per Culler.

Fit the bow handle.

Log of ZSA ZSA.

Thursday, December 13, 2018

Alcort Super Sailfish ZSA ZSA 13 Dec 18 Toe Rail and Rub Rail

12 Dec 18:

Worked on ZSA ZSA's deck, but first a PSA. Here is the remnant of a keeper chain for the $50 horizontal hinge pin of the rudder assembly. They don't keep very well, we suggest attaching the keeper to the rudder vs the deck.

We dredged out the seam a bit with a half moon blade on a DeWALT multi oscillating tool.

There MIGHT have been a leak here, the deck panel was popped loose at the bow. We used our saw to clean out some old adhesive.

New shop stool CARMEN put to work with WALDO.

Busted the mast step loose, someone had attached it with two lag bolts, normally takes 4 #12 bronze screws. It's off now, and we can see that the deck was replaced at one point, probably how the foam blocks got inside back when.

Removed the corroded coaming fasteners.

Used a syringe to inject TotalBoat THIXO thickened epoxy into the deckedge seam. It was easier on my hand to dispense the THIXO and mix it by hand vs using the mixing tip, then trowel it into the syringe. We also filled old fastener holes.

Put a sealer coat of TotalBoat Halcyon Amber Varnish on the mast step.

Made a pattern of the plank with parchment paper.

Sanded and sanded and sanded. 40 grit on the DeWALT random orbit sander and Black and Decker belt sander, lots of old paint to get gone. Smoothed the scarf.

Primary goal was to get the surface smooth and put some tooth on the old paint so it will hold primer.

Started putting some bend in the toe rail. Spoiler Alert! It didn't work.

We interrupt our regularly scheduled program for Trailer Tetris. CYANE's trailer back to the trailer park, SMEDLEY to the driveway.

13 Dec 18:

Dry fit the rub rail, trimmed the lower edge up a bit per Culler style. The toe rail will be trimmed at the bow to make room for the bow handle.

Cut the toe rail down to 3/4 inches wide so it would take a bend. It will cover the top of the rub rail and overlap the deck. Both the rub rail and toe rail be permanently fastened with THIXO and will protect the deck seam. Drilled countersink and pilot hole with combination Fuller bit, dry fit with #6 silicone bronze wood screws. To make the toe rail curve we placed screws every 3 inches, otherwise a screw was used every 12 inches to hold the trim in position. We could have used deck screws for this, we recommend using a screw with a star drive or square drive and to always drill pilot holes, otherwise the narrow trim will split.

The current plan is to remove the screws after the THIXO cures, fill the screw holes with epoxy based TotalFair. Once the trim is on we will slightly round the cut edge so it is not sharp, if we remember we will put it on the outside edge or work it over before it is installed with a thumb plane.

Log of ZSA ZSA.

Small Boats Monthly

Small Boats Monthly is a digital publication put out by WoodenBoat, focused towards folks with boats that can be launched and retrieved easily, maintained and stared at the house.

Articles come from the WoodenBoat staff and from readers. From SBM "We also rely upon our readers—our community—to keep us informed of developments in the world of small boats. These subjects might include new equipment and techniques for boating and camping, people taking interesting trips, new water trails, and surprising topics that we might not have dreamed of."

Each month there is an Adventure Narrative, Boat Profiles, Reader Built Boats, Product Reviews and Techniques. There is also a Classified Section, Events Calendar and News & Curiosities section.

A subscription includes a monthly issue and access to all archived issues, back to 2014 when the publication started.

We subscribed a few years ago and then became freelance contributors, it has been fun working with Chris and the WoodenBoat team to pull together some fun and unusual articles. Our contributions so far:

Penobscot 14

Drascombe Lugger

Muck boots


Trailer Tires
Dynamic Dollies

Insignia Sailcloth
Barry King Mallet

ARTech Flashlight

Nov 2018

Dec 2018
Porter-Cable Cordless Wet/Dry Vac

"Each December, we publish a print magazine called Small Boats. It’s available on the newsstand and through the WoodenBoat Store, and is a selection of the content you’ll find in Small Boats Monthly."

Our Penobscot and Lugger articles are featured in the 2019 edition of Small Boats!

Log of Small Boats Monthly.

Wednesday, December 12, 2018

Small Boat Musings

12 Dec 18:

-If someone wants to build a hay wagon, don't show them how to build an oat wagon - Capn Jack

-Enjoy the moment - Capn Jack

-Don't sail where the birds are standing - Skipper

-Don't fly when the birds are walking - Clark

Tuesday, December 11, 2018

1970s Sailboat from Plans What Is It?

08 Dec 18:

The Skipper's family found plans in a magazine for a 16 foot sailboat in the early 1970s, they built her over the period of several years and then sailed her for many. Centerboard with a pop up rudder, small cuddy. We think the advertisement to order the plans from CT or Boston was in the back of a boating magazine or Popular Mechanics. No one can remember the name of the design. Does anyone recognize it? If so, please add a comment below.

11 Dec 18:

Builder Notes from Capn Jack
-105 sf main, 49 sf jib.
-Steel centerboard was made from stainless cut from a tank at the junkyard on Leopard. The shape was "enhanced" by a hacksaw, "modified" to suit the purpose. He has no idea how much it weighed, but it twas heavy.
-Mast was solid spruce, "Hell for stout" as Mr. Hazelwood would say.
-Rectangular spruce boom.
-Spruce frames, sawn.
-Spruce splashguard.
-Deck and Hull Douglas Fir plywood, exterior grade.
-She made a trip to Wyanet, IL.