1978 AMF Sunfish SUGAR 2 26 Jul 18 Kirby Deck Paint

26 Jul 18:

Catching up the blog. Each layer of primer or paint took about a day, so we skipped posting about each coat. Sanded old paint off of SUGAR 2's deck with 120 grit pads on a DeWalt Random Orbital sander. Fixed one more void on the seam with THIXO injected by a syringe then lightly clamped. Then did another leak test, which she passed.

Put a coat of TotalBoat Gleam Satin Varnish on the rudder, tiller and tiller extension.

Sanded, leak tested, ready for tape, primer and paint.

Removed the bridle eyestraps, took out one screw at a time, swiveled the eyestrap out of the way, reinserted screw, then took out other screw. This helps ensure that the wood backer block inside does not drop off. The blocks are glued and fiberglassed into position, but 40 years later they can come loose. Sometimes excess expanding foam holds them in place.

Taped off the bow and stern and brushed on Kirby Primer tinted with #4 Orange with a short handled sash brush. 2 coats.

2 coats of Kirby's #4 Orange, it went on smooth with a brush, 100% in 90F temp. Color is awesome and so is Kirby's Tech Support, George answers the phone!

Skipper peeled the tape!



Removed the cockpit trim, 1/8 inch drill bit to drill out the head of the rivet. A wide, flat screw driver is handy to tap the trim loose. Sometimes a remnant of the rivet is stuck in the fiberglass, like you see on the far left of the photo, we used an awl and hammer to tap that piece out.

We've enjoyed using the Kirby Paint. They have been making paint since 1846 and custom mix the colors. It has been easy to use, levels well and the colors pop on this boat.

Before we did the deck we sprayed the perimeter and cubby of the cockpit with light gray Rust-Oleum, it was east to reach far corners with the spray. On the non-skid portion we brushed on Kirby #25 Light Gray.

Kirby White Primer on the mid deck then first coat of Kirby's Maynard Bray Off White. Primer brushed and then lightly sanded with 120 grit. Paint rolled with a Mighty Mini roller and tipped with a Corona Deck and Trim brush. Very happy with the results!

Applied the US Navy Fixed Wing Flight Training Squadron 27 (VT-27) markings.

Restoration Log of SUGAR 2.

1982 AMF Sunfish PHOENIX 22 Feb 18 Leak Test and Deck Repair

22 Feb 18:

Phoenix needed a little TLC, she had a few leaks and we did an air leak test to figure out where the trouble spots are. We found several, the 2 big culprits being in the bailer hole seam and the daggerboard trunk. The funniest was Mt Vesuvius blowing out the rivet hole in the coaming.





We sealed up those areas with Pettit Flexpoxy, and we also put Marine-Tex epoxy putty over several areas where gelcoat had chipped.

We also sanded the coaming in prep for paint and installed the aluminum cockpit trim that our buddy Alan sent us.

Log of PHOENIX.

Daggerboard Trunk Repair and Leak Test

Our Sunfish Madison had damage to the daggerboard trunk on the hull, gelcoat was chipped and a previous owner had repaired the area with epoxy. The epoxy had flaked away and we could see exposed fiberglass, still encased in epoxy but the last layer of defense against leaks. We didn't notice any leaks but wanted to check for leaks and repair the area.

From Small Boat Restoration 2013

We did a leak test with a mix of dish soap and water, recommendations say 50/50 but that seemed like a lot of soap to me. We put about 1/4 cup of soap with a gallon of water and it was plenty soapy. For the leak test you blow air into the hull vent hole, which is located on the forward wall of the cockpit. The key to putting air into the hull is to use very low pressure and very low volume. You can blow air into the hull, use a bike tire pump or a compressor set to low pressure. CAUTION: if you put too much air into the hull you can split the deck/hull seam or inflate the boat enough to break the foam blocks loose. Then you'll have more repairs! Blow a little air into the hull, stop and put your hand by the hole to see if you can feel the air coming back out.

From Small Boat Restoration 2013

From Small Boat Restoration 2013

For this leak test we put the boat on its side and drew a soap bubble across the top and bottom slots of the daggerboard trunk. We also soaped up the inside of the trunk. We were looking for bubbles around the openings and also to see if the bubble over the trunk openings grew. There are a lot of static bubbles from the soap mixture but it will be obvious if air is escaping, a large bubble will grow or so will a bunch of small bubbles. For our test we found no leaks in or around the daggerboard trunk.

From Small Boat Restoration 2013

From Small Boat Restoration 2013

We did find leaks around the halyard cleat and the inspection port!

From Small Boat Restoration 2013

Once we were done playing in the bubbles we washed off the rest of the boat and mixed up a batch of epoxy putty to repair the area. Some people use plain epoxy, we like Marine Tex or West Marine RX epoxy putty because it comes in a small size and it is colored white, which matches the Sunfish white gelcoat pretty well. You can find epoxy and gelcoat kits in your local marine supply store, also online and at my local Ace Hardware store. Amazon has a good price if you are thinking ahead :)

From Small Boat Restoration 2013

We use a low tech paint stir stick broken in half lengthwise to apply the epoxy, that we we can reach up inside the trunk if needed. The inside of the trunk often has epoxy chips that expose the fiberglass and also gets damaged during groundings.

From Small Boat Restoration 2013

From Small Boat Restoration 2013

We want to remove excess putty so we dont have to sand it off later. You can use a plastic putty scraper to smooth out the surface a bit, or a good ole finger. Another trick is to put wax paper over the putty, smooth it down then remove the paper.

From Small Boat Restoration 2013

We mixed up the entire 2 oz of putty, so we looked for other gelcoat chips to repair. This area has impact cracks in the gelcoat from being struck by a very solid object. The cracks are in the gelcoat and not through to the fiberglass, so they can be left alone for now, we will keep an eye on them. Madison went through several hurricanes stored outdoors, notably Ivan and Dennis, so there is no telling what all she stood up against. After the putty dries we will sand off the excess.

From Small Boat Restoration 2013

Once the putty dries we use a 4 in 1 file to knock off the excess and get the repair moderately smooth. I like this file because it can be used for rough and moderate filing, and it has both a flat and half round side, perfect for the sides and ends of the daggerboard trunk. A friend uses a power drill with an extension bit and sanding drums, we may graduate to that next. I do the final sanding with a power sander in the areas I can reach.

From Small Boat Restoration 2013

From Small Boat Restoration 2013

From Small Boat Restoration 2013

After sanding I applied some Interlux Brightside Bluglo White. It will darken up after a little time.

From Small Boat Restoration 2013

Repair is finished and Madison is ready to sail!