Everest 1 Cherub

[Torchy]

The only laminating that I expect to do is the taping of the deck and wing joints.

This sounds like something I asked about earlier in the year and got a negative on...this boat could be built from a kit of pre-laminated parts, yes?

...but currently because some of the parts are an expensive type of carbon sheet it wouldn't save money?

I was hoping pre-laminated carbon sheets were the new plywood.

[phil_kirk]

Clive,

It sounds like you have really thought the build through.  I'm in favour of a boat which can be built as a kit of parts.  We laminated the flat panels for our bulkheads from one sheet of foam.  I built a flat bed of timber joists and plaster board to laminate the flat pannels on. I vac bagged the panels and weighted the bag down onto the flat bed.

The kit boat concept allows, as you have suggested, a quicker build and less initial laminating competance.  Just having accurate templates of all the flat components for the E5 build would have saved a lot of time.

With there being a lack of second hand 05 rules boats this concept could allow the class to grow more rapidly.

[Torchy]

Clive - it occurred to me that the big advantage of racks is that you have two trapezing positions - either from the hull or the rack. This makes getting in and out easier. I might go as far as fitting a (rear) foot stop to Loco to help the helm come in smoothly...currently there's nothing to stop you until the leeward gunwale...

Wings might mean you just adopt 49er tactics and walk around but just something to think about.

[Clive Everest]

The mould is all assembled.

It took about 8 hours to assemble. I suspect that a perfectionist would have taken longer.
If I was doing it again I would have had even more bulkheads. I had them every 370mm and the 6mm ply planks were not 100% stable between them. I could have used thicker planks but they might have become harder to twist.
Thicker bulkheads would have been easier to hit with a tack when tacking it all together.
The ply planks fitted to the form accurately however they needed to be positioned carefully.
Next time I will put castelations on some of the bulkheads and notches on the planks so that they lock together with everything positioned exactly.

If you look at the Transom view above, Nigel, I am planning some pretty big kick bars.

Clive

[Clive Everest]

The mould is now with Pete Jary at Zest racing.
He is going to do a bit of fairing on it and glass sheath it to make sure that it is going to be vac tight.

[Clive Everest]

I hope to mould a shell next weekend.

[roland_trim]

Looking good Clive.

Is the fairing so the facetets in the original jigsaw will dissapear in the wood/plug or is the idea they will they be erased when sanding the foam core?

[Clive Everest]

I intend to keep the facets in the mould. The foam has been cut to the same pattern so there will be no compound curvature in any piece of foam.
This should make it much easier to put the foam down.
I will then loose the corners by sanding the foam.

A small amount of fairing is needed where the ply planks were not quite stiff enough, and the bulkheads too far apart so that the edges of adjacent planks have not exactly aligned.

It was quite impressive watching the water jet cut the foam.
It was able to cut at 1-2m/sec each plank was produced in just a few seconds.


 

[Will_Lee]

You are going some, Clive!

W

[Clive Everest]

At my age anything else could be very risky.

[dave_ching]

This looks amazing,
My only complaint is your use of solid wings.
As I already have a long list of work to do on EJ and adjusting wings was one of them now it looks like they will be solid aswell.
It is something I always thought made sence though I couldn´t put the argument aswell as you.
The best thing is seeing new ideas in the class.

[Clive Everest]

I have just had a very productive long weekend working on the boat with some great assistance from Roger Angell.

[Clive Everest]

After the first cure we long boarded the foam to make sure that it was fair and that the turn of bilge was a smooth curve.
this was about 2 hours work.

Getting the hull off the mould was very difficult.
I suspect that the mould should have had a bake before being used. I think that it all changed shape very slightly during the first pre preg cure and that this locked the hull on.
It probably did not help that we got impatient and wound the bake up to 100C.

At one stage I thought that we were going to have to take the mould apart to get it off.
You can see dents on the back of the boat where we were driving wedges in to try and get it off and this was after releasing the top sides all the way round, and using PTFE release film.

The hull shell weighed 6.98kG off the mould.
The FibreFusion internal parts all fit nicely straight off.
The wings and deck appear to fit as well.
There is not much more I can do until I get a centreboard off composite craft to make a case around.
So it is now unlikely to progress significantly until after the inlands.

[roland_trim]

Cracking on at pace. Not a bad weekends work!

[Tim Noyce]

Very nice indeed. Looking forward to seeing this come together... (not that we will have to wait long at this rate!)