1965 Alcort Sunfish WAVE 04 Dec 20 Jigsaw Puzzle Sunfish Style

 04 Dec 20:

Let the jigsawing begin. 2 decks to make one.

Skipper scribed the cut line for the new deck piece using a calibrated Sharpie.

I tried to talk Skipper into leaving this as the finish scheme, but she wants to paint the new piece to match.

We cut out the new deck piece then used it to draw lines for an internal backer plate.

The new deck piece will rest on the hull flange and backer plate. 

Aft section of backer plate fastened with TotalBoat 5:1 High Performance Epoxy, thickened with silica filler to peanut butter consistency.

Sanded the seam of the replacement deck piece to remove old polyester resin. 40 grit on a DeWALT 20 Brushless random orbital sander, dust extraction with the Porter Cable cordless wet/dry vac.

WAVE's bow fastened to the deck with THIXO Wood thickened epoxy. Why Wood? Because we had some. It is the same as THIXO but has wood flour added to better match wooden boat repairs. WAVE thinks she is a wooden boat now. Skipper used her rubber mallet to tap the bow piece back into position, we were able to mate up the fractured edges of the bow piece nad deck using the stripes as alignment marks. Dry clamped for now. PHOENIX waiting patiently for her turn, glad that WAVE is the guinea pig.

Fastened the bow piece to the backer plate with THIXO Wood light clamping. Sandbag is keeping the new seam flat, filled with QUIKRETE 50-lb Play Sand. It is important to use QUIKRETE 50-lb Play Sand because....you're still reading....For more info visit www.icantbelieveifellforthis .com

Backer plate epoxied, clamped and drying.

Bow refastened with THIXO Wood thickened epoxy. 

Sandbag to keep the seam flat.

While the epoxy is drying, we piered out another 8 feet.

The end is far away. And the cone.

New flag in the near future, we'll be able to get to it from the dock instead of the Sharknoe!

Log of WAVE.