UK-Cherub Forum
Cherub Chat => Tech Chat => Topic started by: PaulJ on October 05, 2012, 03:48:25 PM
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As it seems to be the week to announce new builds, I thought I would let everyone know about our new boat (Ellway 7) that will be starting construction at Composite Craft on the the Isle of Wight in the next week or two. Initially the aim was to take a standard E6 and produce a crew deck that was wider and lower than the current E6s to make the boat a bit more user friendly. Once we got going though and decided that a new hull mould was going to be needed we ended up tweaking it a bit.
Quote from Kevin Ellway :-
"The E7 is a subtle development of the E6. The changes should produce a hull which has an even smoother transition between displacement and semi planing sailing that occurs at around 6 knots. It should also be a little quicker offwind. The sheer and decklines have been modified to give more room in the boat for both the crew, kite and deck gear."
The boat will be built in a centreline split female mould from prepreg carbon and 8mm Nomex, the bulkheads will be of same construction and will be cut using their in-house cnc machine. The crew deck and half foredeck will come off an International 14 mould that they currently own. We haven't fully decided how the mast step and wings will be built but they likely to be a one piece bridge deck moulding that bolts down. We are trying to cut down the number of parts to keep build time and therefore cost down to a minimum.
We will be taking the current tried and tested rig off Ronin for the new boat. Both Clive and I are having the same foils, T-foil as per Ronin and Riot Van, the daggerboards are the same profile as Ronin's but with a new lower drag Hollom section.
Composite craft are keen to get involved in the class and are looking to offer an E7 kit that can be finished at home, this would be in wet layup carbon on foam and would include the hull moulding, crew deck and foredeck moulding ready to trim, rectangular daggerboard case, CNC cut bulkheads, one piece bridge deck, aft wing bars, simple CNC cut build jig, designers royalty fee, hull mould hire fee, build manual and photos, this is anticipated to be approximately £4500 + VAT.
Various hull renders below from Kevin.
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Fantastic Paul...the class is really growing
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Likewise - thanks for keeping us all updated.
W
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Looking forward to seeing this take shape Paul!
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The new female moulds for the Composite Craft daggerboard are now finished. First board should be out by early next week
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Peter might have to grow a few inches taller to pull that one up when coming into land :)
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Is that a wing sail in disguise?
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Latest CAD image showing the rudder gantry and inward rolled gunwales that are incorporated into the female mould. The mould parts have been CNC cut, assembly is underway
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How do you get the hull out of a female mould with inward rolled gunwales? I must be missing something (as usual).
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How do you get the hull out of a female mould with inward rolled gunwales? I must be missing something (as usual).
The mould is built in two halves with a bolted joint down the centreline of the boat. the mould is then split to release the boat.
Apparently the first half is built and faired, awaiting pictures, the moulding surface is made up of 2 layers of 3mm modelling ply. I believe this is made up of individual plys orientated at 45deg which allows it to bend easily, the tight curves are made from strips of ply. The next step is to laminate the moulding surface with 500g biaxial carbon cloth, it's all then cooked in the oven for a few hours so that everything remains stable when the hull is cooked.
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Latest progress photos from Composite Craft, both the mould halves are finished, just the final fairing to be done. The port side half was still cooking at 40deg when we visited but Peter managed to get a quick photo.
The pole is also coming out of a split female mould but will be about 600mm shorter. Note there is no reason for the red and green gelcoat, it's just what they had left at the time.
Hull lamination will start sometime in the week after the inlands
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Female mould has been bolted together and the centreline joint faired. The Rudder gantry mould is complete and is ready to bolt onto back of the mould.
The next stage is to apply the release film, this is a lightweight glass cloth with a teflon coating on one side and a sticky back on the other, using this saves both time and money, as the mould doesn't need polishing or use any release agent. Apparently the release film is good for 10 boats
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Good progress is being made at Composite Craft, hull shell and gantry laid up and cooked last week.
Hull laminate 600g/m2 outside laminate, made up of 2x 200g uni, 1x 200g bi-axial, 8mm 25kg/m2 Nomex, 400g/m2 inside laminate 200g uni, 200g biaxial, plus some local reinforcement around the main bulkhead.
Bulkheads 8mm Nomex with 500g biaxial each side.
Centreboard crash box and minor bulkheads bonded in, main shroud bulkhead will go in this week. Moulds for the wing bars, mast post and deck will start this week.
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Nice to see it coming along smoothly. She's certainly gonna be pretty stiff.
Have you decided on a paint scheme yet?
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Deck mould nearly completed, just a bit of HD foam required for the bow, then a 500g carbon skin. Should have a deck by the end of next week.
Colour scheme not decided on yet, not going to be that radical now
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Hi Paul, looking good! Will you be able to eat Christmas dinner off it? I bet you are getting quite excited... I was looking forwards to the radical paint job - My eldest, Emily, is studying contemporary fine art and her bo is part of a graffiti gang, I am sure they are cheap!!!
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A graffiti cherub, that would be cool!
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Maststep design has now been finalised, the pole will pass through the tunnel. The lower parallel section will be installed below the deck to transfer the loads to the bulkhead and hull structure.
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How are you going to lift the dagger board when the pole is in? Pretty sure if atums was in the middle we'd have some problems
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How are you going to lift the dagger board when the pole is in? Pretty sure if atums was in the middle we'd have some problems
The daggerboard is far enough back to allow the pole to be fully retracted without hitting it. The pole will also be inside a pole sock which has a webbing strap on the aft end to prevent the pole from going too far back. The sock also prevents all the knitting in the bow from getting tangled in the pole launch line.
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We have a pole sock on the underside of our kite sock. It does help to guide the pole and it does keep all those possible tangles at bay. With 300mm of pole sticking out the front as the rules require I can see a normal length pole not clashing with the board. The elastic take ups on our kite sheets stop our pole going too far back but do allow the pole to be retracted close to the bow for towing.
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All the bulkheads have now been installed and over taped, the whole lot has been post cured for a day. Deck mould complete and the deck is being laid up today.
Allen Bros delivered all the fittings for both boats last week.
T-foils have arrived from Demon Yachts
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BOTH boats?
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Latest progress
Mast step completed, approx 1.8kg when trimmed up, also useful if auditioning for Star Wars
Wing Strut mould nearly finished, one mould is used for all 4 struts, transitions from wing section outboard end to a square section at the inboardend
Hardpoints and blind nuts being set out in the deck
Will - the fittings are for both mine and Clive's boat
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Coming along nicely Paul! The Darth Vader helmet is a lot bigger in reality than I expected it to be from seeing the CAD image! Is it a one size fits all, or are they made to measure dependent on head size?
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Tim - the mast step is like an ice berg most of it is below the surface. We also need plenty of space to attach all the fittings for the adjustable rig. Deck going on as we type. Each sale of the helmet comes with a free E7 cherub according to Peter
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The boat is out of the mould and progressing very well, on target regarding weight as well.
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Looks fantastic.
Great see a Henry sitting in prime positition as well.
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The hull is coming along very well, should be ready for paint early next week, more photos tomorrow
I have made a couple of the minor parts which seem to take a surprising amount of time
1. Wing bar forward ends, these will have all the rig control take aways passing through them into the wing tubes. The blanks were water jet cut with Clive's stuff and then faired by hand
2. Jib tower parts, again water jet cut, just need a bit of the surplus wing tube to finish. The tower has been designed to allow 360deg rotation
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I really like those rack tube ends. They look great it's a shame you had to make them, but top job.
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Latest build photos, on the home stretch now, a few minor item such as cleat shelves plus a bit of paint.
Transom showing the cutouts for the aft wing bars which are supported aft of the transom to increase the space in the cockpit
Bow showing the carbon plate for the forestay and pole sleeve all finished
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Crew deck just prior to the two kick bars being glued in, jib track with 3 point attachment and pole sock in place
Rack tube jig in place ready for the installation of the wing bars
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Looks like you're making big progress there Paul. Some serious quality building in the class in the space of 2 or 3 years now - bodes well for the future.
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Jib tower all finished and ready to go.
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boat all painted and grip templates in position.
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Very, very nice...
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Very, very nice...
Missing a few verys on that post.
Looking great,
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Tres bon indeed! Looking forward to seeing it in person later in the week! ;D
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Superb. Red ones are always faster.
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Looking good!!!
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Will she have been sailed by the boat show? Would be great for the class to get that trophy again.
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We plan to launch her on the Sunday before the dinghy show, weather permitting !!
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Looks awesome Paul. Great colour choice Peter.
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Good progress this weekend, fitting out nearly finished, got the rig up and tensioned, 250kg :-)
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Photos courtesy of Hannah. Wings bars need a bit of trim and some glue !!
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Awesome! :)
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You have been busy! Looks great!
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Very nice job Paul,
I can't wait to see it in the Carbon. I am sure all the effort and attention to detail will pay off with a super reliable boat. Would love to see a photo of the boat on the water if that is possible.
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We are still aiming to go for launch on Sunday. Stills loads to do plus the weather doesn't look like it will play ball. Hannah is coming out in a rib to snap away, plus we may get the go pro set up as well.
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I'm actually looking forward to a dinghy show, can't wait to see these.
Couple of questions:
Does you board have a square top?
plus we may get the go pro set up as well.
Are the black angles at the front for tech?
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Paul,
I'm delivering the Tres to a new owner in Ramsgate on Sunday early afternoon...will you be launching at Weir Wood?
Roughly what time? (interlopers with [2nd] video camera welcome?)
Mine's a cheapo ATC mini but still reasonable quality, can be a headcam or mounted around eg mast,
N
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Roland. The daggerboard is a normal shape and fIts into a cassette that is currently removed, this acts as a crash structure in the event of a grounding. It also allows the daggerboard to be moved fore and aft 50mm or so .
The forward carbon bits were for the rig controls but are now not required and are due for removal in the near future or conversation to drinks bottle holders
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Paul,
I'm delivering the Tres to a new owner in Ramsgate on Sunday early afternoon...will you be launching at Weir Wood?
Roughly what time? (interlopers with [2nd] video camera welcome?)
Mine's a cheapo ATC mini but still reasonable quality, can be a headcam or mounted around eg mast,
N
Torchy - yes launching at Weir Wood on Sunday will be there most of the day, Maff may be along as well with video. Weather looking variable so check back on Saturday night for go no go
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Will do
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Looking very nice, can't wait to see it on the water!
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Roland. The daggerboard is a normal shape and fIts into a cassette that is currently removed, this acts as a crash structure in the event of a grounding. It also allows the daggerboard to be moved fore and aft 50mm or so .
That is a very neat idea.
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I had been considering a similar thing for Loco so that boards with different sections can be used....this is because Loco has a 'fat' slot and I'm planning to make a skinny board - I hadn't thought of enlarging the slot in the boat tho'...hmmmm....neat.
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The cassette is machined from foam (1 side only), laminated with a couple of layers of glass and then two halves are glued together with a carbon capping. Note that there is also a cardon plate inset flush with the bottom of the hull.
The cassette won't be bonded in permanently just a couple of dabs of sekaflex to stop it lifting out with the daggerboard
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Launch delayed until after the dinghy show.
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OK
Shame...no Prix d'Elegance bid
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After a visit from Graham on Sunday, we now have a plan B
If the weather plays ball we will briefly launch on Friday afternoon have a quick sail and then pack up and head straight for the dinghy show. We still have 28 items on the to do list though :-) to complete before adding water
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That's only 7 a day, or about one an hour, should have time for a cuppa inbetween !
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I had been considering a similar thing for Loco so that boards with different sections can be used....this is because Loco has a 'fat' slot and I'm planning to make a skinny board - I hadn't thought of enlarging the slot in the boat tho'...hmmmm....neat.
Loco was designed with the same box system, so there is a box under the floor. All be it a lot further forward than the current board position. We moved it a long way back after initial sailings. If I remember correctly.
(http://farm9.staticflickr.com/8373/8509184447_2391f9ea2d_o.jpg)
(http://farm9.staticflickr.com/8369/8509184425_0a306d6654_o.jpg)
You can see the old board position here -
(http://farm9.staticflickr.com/8238/8509213743_17d15bf3a8_o.jpg)
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Thanks Daryl...and thanks for the higher res version of that iconic capsize. One for my gallery
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Cool Beans hits the water just prior to the dinghy show, all went well, plenty of fine tuning to be done though :-)