TotalBoat from Jamestown Distributors

 01 Jun 23:

We have spent over a decade with the Jamestown Distributors Tech Team, ordering a variety of supplies through the years and along that trail we started using several of their in-house TotalBoat Products. We bought a lot of THIXO thickened epoxy adhesive, epoxy resin, hardeners, fillers, WetEdge paint, primer and our favorite, TotalFair fairing compound. They also have polyester resin systems. We shared photos with the team of our restoration process, and now we mutually support each other and share information on products we like. As Ambassadors for 7 years now, we have a new custom link to the TotalBoat webstore, which if you care to use it offers a 5% discount on items purchased. And as always free shipping.

totalboat.com/smallboats

Here's an adhesive we like, THIXO Wood. I smiled when I saw our photo on the website, from a deck repair we did to our 1953 wooden Alcort Sunfish ZIP. The THIXO (thickened epoxy adhesive) dispensed from a cartridge takes out all of our guessing of mixing the right amount of resin, hardener and filler, and the mixing tip does the mixing for us. Also less time exposed to a cloud of filler dust. Leave the tip opening small for a small bead or cut the tip back a bit for a wider opening and let her rip! Once finished, just leave the tip on the cartridge or replace the cap, THIXO stores well, and when it's time for the next paste party put on a new tip and have fun.

PS: Speaking of paste, Skipper LOVES to paste. If she is nearby I better offer the pasting honors to the little pirate first. If I don't, I won't be walking the plank, I'll be running and screaming off of the end of it.

Did we mention free shipping on TotalBoat products? And you may or may not know of all of the other products that Jamestown Distributors sells, we've bought a little of everything from them. Another favorite for our shop are the Redtree Fooler brushes. JD ships fast with nice cardboard packaging, that we reuse for a variety of things, like backers for internal fiberglass patches on Sunfish or templates around the shop. 

We're always happy to answer questions in the comment section and hear about your favorite tips. 

Fair Winds,

Clark and Skipper

Nutshell Pram EXCUSE ME 24 Jun 22 Making the Mast

 24 Jun 22:

The Nutshell Mast is 8' 5" long, and the widest diameter is just above the base where it flares to 2 3/8". The bulk of the mast is 2 1/8" though, so we decided to make the blank 2 1/8" and save on some carving. It should be plenty strong, as a comparison our Sunfish mast is 2 1/4" diameter and it carries 75 square feet of sail, twice that of the Pram. We just have to remember down the road to cut the mast thwart hole to 2 1/8". 

We cut 2 pieces to length, then ripped them 2 1/8" on one side and 1 1/16" on the other. For adhesive we used TotalBoat THIXO Flex dispensed from their 2 component epoxy resin and hardener cartridge in a 25:1 High Thrust Caulk Gun. 2 beads of epoxy per face then we spread it with a paint stir stick to ensudre full coverage.

Video: Gluing the Mast Halves

We laid down some plastic sheet to keep the mast from sticking to the floor, a little of the plastic stuck to the epoxy though, not an issue as it will be sawed or sanded off. Poly sheet would work better. We clamped the mast every foot or so and used the plywood floor edge line as a visual guide to make sure the mast blank is mostly straight

When tightening clamps a small amount of epoxy squuezeout should be seen, then it is time to stop clamping, the thickened epoxy has filled gaps at this point. Any further clamp pressure could force epoxy out of the joint. Plus as the wood absorbs the epoxy some of that small bead will be drawn back into the seam.

Here is a small spot where no epoxy squeezed out, so we later added a dab of epoxy with the caulk gun.

Log of EXCUSE ME.

 

Pascagoula Diamond Bottom Catboat MARGARET ROSE 12 Jul 20 Inner Stem

12 Jul 20:

To make the inner stem for our Pascagoula Diamond Bottom Catboat MARGARET ROSE we cut 4 layers of 3/4 inch cypress. Each layer was made from 2 pieces cut from 12 inch wide stock, and we alternated seams each layer. Layers were glued together with TotalBoat THIXO Wood, a thickened epoxy dispensed with a Newborn 18:1 Hight Thrust caulk gun. We put in several temporary deck screws to keep the 8 bits from sliding around and clamped until we saw a small bead of epoxy squeezeout along the seams. Too much clamp pressure could squeeze out all of the adhesive.

To make the inner stem for our Pascagoula Diamond Bottom Catboat MARGARET ROSE we cut 4 layers of 3/4 inch cypress. Each layer was made from 2 pieces cut from 12 inch wide stock, and we alternated seams each layer. Layers were glued together with TotalBoat THIXO Wood, a thickened epoxy dispensed with a Newborn 18:1 Hight Thrust caulk gun. We put in several temporary deck screws to keep the 8 bits from sliding around and clamped until we saw a small bead of epoxy squeezeout along the seams. Too much clamp pressure could squeeze out all of the adhesive.

Video: https://youtu.be/OUxxq8TAmAY



2 part thickened epoxy adhesive dispensed from an 18:1 High Thrust caulk gun, the resin and hardener mix in the mixing tube. That saves an enormous amount of time, we skip the measuring and mixing and filler dust. #totalboat

We aligned the 8 pieces and drove in a few temporary deck screws to keep the pieces form sliding around under clamp pressure. Then clamped with light pressure until we saw small beads of epoxy squeeze out of the seams. Next we smoothed the excess epoxy down to ensure full seam coverage and to reduce finish sanding later.

Jamestown Distributors donated the TotalBoat THIXO to MARGARET ROSE, we appreciate their support and love the simplicity and speed of THIXO from a tube. #totalboat

Care package for MARGARET ROSE! Jamestown Distributors donated 5:1 Epoxy resin with their Special Clear Hardener and silica filler, WetEdge colors Sea Green, Black and Bristol Beige, Gleam Satin varnish and a lot of THIXO Wood. We'll use the epoxy mix for larger batches, and the Special Clear Hardener will save time when we seal some pieces like the inside of the centerboard trunk. The Special Clear Hardener will not blush, so we don't have to rinse between coats.

TotalBoat ships free in CONUS. FMI: Jamestown Distributors Tech Team (800) 497-0010 Try our discount code LEWISBOATS if you have a JD account and check out online.

Log of MARGARET ROSE.

1953 Alcort Sunfish ZIP 11 May 20 TotalFair Fairing Compound

11 May 20:

Faired the screw holes and low spots on ZIP's letterbox repair with TotalBoat TotalFair 2 part epoxy fairing compound. The blue and yellow resin and hardener mix in equal parts to make green, and we use a plastic spreader to apply it.

We try to get the compound as smooth as possible but leave a little extra on top, to be smoothed with sanding.



Log of ZIP.

1953 Alcort Sunfish ZIP 24 Apr 20 Hull Repair Supplies

24 Apr 20:

Gathering supplies for ZIP's hull repair.

THIXO Wood for the letterbox scarf. TotalBoat Wet Edge Fire Red for the repaint, using Mighty Mini roller kit, all from Jamestown Distributors.

1/2 inch A/B marine grade plywood.

Log of ZIP.

1965 Alcort Sunfish WAVE 25 Nov 19 TotalBoat Topside Primer

25 Nov 19:

Trimmed the strings and removed the paint sticks, sometimes bits get left behind in the epoxy. Those will get sanded off.

WAVE was moved outside on the finishing dolly for sanding with 60 grit on our random orbital sander, we used the French doors today.

Sanded the repair areas to get them flush. While I was sanding I found an area that I missed, so I made another blind hole patch for that.

WAVE is all different colors, which makes it harder to see areas that need to be faired, so we put on a "Show Coat" of primer, to show us where the hills and valleys are. We used TotalBoat Topside Primer applied with a Mighty Mini roller cover, all available from Jamestown Distributors.

She's mostly one color now!

Log of WAVE.

1963 Alcort Sunfish CHIP 19 Jan 19 TotalBoat THIXO and Elixir

19 Jan 19:

We received some free goodies from Jamestown Distributors to try out on CHIP. We will use the TotalBoat THIXO thickened epoxy to fasten the new plywood bottom, dispensed from a caulk gun to make the job go quick. JD also sent some of their new Elixir paint to try out, Fire Red for CHIP's hull, to be applied over the gray primer. I'm most excited about the soap and water cleanup for the paint! If the Elixir red is close to the brilliance that their WetEdge was, we have a winner. The cap and bag storage should help the leftover paint to last longer too. We also got some aluminum paint, in case we need to paint SCOUT again any time soon.

JD always adds free cups, stir sticks and latex gloves to the order, TotalBoat ships free in the US with a small surcharge sometimes for hazmat.

Log of CHIP.

TotalBoat Stocking Stuffers

04 Dec 18:

Early Christmas! We have been trying out many of the products from Jamestown Distributors' TotalBoat line, blogging about them just as we do about other products, tools, materials and techniques. So far we have been impressed with the quality and price, and as always the Tech Support. Restoration costs can add up, so we like that most TotalBoat ships free. We bought and tried enough of it that we became Ambassadors, sharing our projects and experiences with JD to in turn share with others. We were excited today to get two boxes of favorite items to use on our projects and a few new items to try out, the WetEdge Cold Cure, Halcyon Amber Gloss Varnish and Elixir water based enamel. Several of the products are now available in resealable bags, that should reduce drying of the product in storage after some of it is used. Jamestown Distributors also sells our other time tested products, Pettit, Interlux and Rustoleum.



Our thanks to Jamestown Distributor for sharing their products and technical expertise with us. We are excited to be part of their Ambassador Program and happy to answer any questions that anyone has with their restoration projects.

Alcort Super Sailfish ZSA ZSA 26 Nov 18 Hull Fairing

26 Nov 18:

Picked up the sheet, halyard, bridle and bow line from West Marine, New England Sta-Set.

Trimmed the bottom panel edge with a flush cut metal blade on a DeWalt multi oscillating tool, used the metal blade because I needed the flush cut. Trimmed it as close as I dared then finished with a Stanley #5 jack plane and light passes with a Black and Decker belt sander. Sanded the fairing compound with 60 grit on a DeWalt random orbital sander

The rub strip is rotten in one spot so we will scarf in a new strip. We started by cutting out the bad part, eyeballed a 45 degree cut and made it with the oscillating tool. The bow is to the left, so we angled the forward end of the scarf so it would overlap aft....

...and angled the aft scarf so the rub strip will overlay it.

Peekaboo.

The wooden Sailfish and Sunfish have a stainless rub strip that wraps from the tab on the bow handle, around the stem and aft 18 inches. Speaking of bow handle, it is different than the fiberglass boats that do not have the tab, or the keel strip. We used the rub strip off of our wooden Sunfish CHIP as a guide, ZSA ZSA's was missing so we need to order a new piece of 1/2 inch, half oval strip. To fit the metal rub strip with used a 3/4 inch long handle hand chisel to bevel down the wooden keel strip, and cleaned that up with the jack plane.

Sanded with 60 grit and ready for primer.

We applied TotalBoat Topside Primer, rolled the bottom with a Mighty Mini Roller kit and brushed the sides with a Redtree Fooler chip brush.

Log of ZSA ZSA.

Alcort Super Sailfish ZSA ZSA 23 Nov 18 Bottom Panels and Hunter Skeg

23 Nov 18:

Attached the final 3 bottom panels to our Super Sailfish. We used TotalBoat THIXO (thickened epoxy) in the seam, ran a bead around the sides and keel, and another bead on the edge of the panel, that should help ensure complete coverage. One bead down one glueing surface is not enough, as the wood soaks in some of the epoxy and might result in a glue starved joint. When the panel goes on we look for a small bit of epoxy to squeeze out, that tells us the joint is full and there is enough pressure on the panel. It took about one tube of THIXO per panel. I like the THIXO because the consistency is perfect for this application, and it is handy to dispense it from the tube in a nice bead, that minimizes epoxy being smeared everywhere and optimizes keeping epoxy in the joint.

Once the panel was positioned we drilled pilot holes and fastened it with 7/8th inch #14 silicone bronze ring shank nails, supplied by Jamestown Distributors.

Keel strip fastened by drilling a pilot hole and counterbore for a 1 1/2 inch #8 silicone bronze wood screw with a Fuller combination bit. These screws use a Forstner bit. Screws and Fuller bit set also supplied by Jamestown Distributors.

Took a break between panels to see if we could trim the bottom panel with a flush blade on a DeWalt oscillating multitool. We could get close if we were careful. Sanded with 60 grit on a random orbital sander.

Back to drilling pilot holes for the nails, the template we made worked out great on the straight sections of the hull.

When we got to the curves at the bow we found it best to offset the template from the nailing line and use it as reference for the holes, otherwise we couldn't follow the curve.

I was told that only the Great Spirit can make something perfect, so goof ups are welcome on our boats. I made sure there were several, as tribute. And it gives the Usual Visitors something to look for.

Spacing for the keel strip screws was 6 inches, shhhh, don't tell anyone that Alcort recommends 7.

There is a 18 inch keel band that attaches at the bow, it is a continuation of a tab on the bow handle. We need to buy some more quarter oval strip to make on for ZSA ZSA, the one shown belongs to CHIP. While we are here, check out the keel strip or skeg. ZSA ZSA had a deep skeg that fit between the bottom panels, the Sunfish CHIP had a short skeg that covered the panel edges. I asked Skipper for guidance on how to make the new skeg, she said keep it tall and add the overlap, and call it the "Hunter Skeg" after her sailing ancestor LT. Ben Hunter. The Sailfish does not have much draft to aid in lateral resistance, the skeg should help with that and aid in tacking.

All 4 panels epoxied and nailed. Hunter Skeg fastened. 2 boards over the scarf joints to hold light pressure while the epoxy cures.

Log of ZSA ZSA.

FMI: Jamestown Distributors for boatbuilding supplies
Great Spirit Boatbuilding Criteria

Alcort Super Sailfish ZSA ZSA 01 Nov 18 Bilge Repair and Paint

31 Oct 18:

Removed corroded fasteners from deck butt joint.

Reinforced the deck beam.

New butt joint, sealed with TotalBoat THIXO.

01 Nov 18:

Removed an extra doubler, reduced weight.

Sealed up old fastener holes with TotalBoat THIXO.

Repaired keel batten.

Fastened keel batten with silicone bronze screws.

Sealed bilge seams with THIXO the applied a coat of TotalBoat Wet Edge Blu Glo White to protect plywood.