Obviously, I haven’t kept up on this blog. I have been busy. I have also made a lot of changes to Gemini. Over the next couple of days, I will update as many changes as I recorded.
You can see from the photo that I have attached the first of six pieces of formica/ply.
There are three pieces on each side, the inside of the aft cabin and outside. The procedure begins with fitting followed by determining how I’m going to brace and provide pressure to make it stick to the wall evenly.
I cover the exposed wood of both the wall and the formica/ply with a coat of resin. While that is setting, I prep the the cavacil (resin mixed with silica (crushed fiberglass)) by placing about a quart of the cavacil onto a beer flat. A beer flat is the cardboard bottom that multiple six packs are carried with. I then apply, using a trowel, the mixture onto both the formica/ply laminate and the main wall. This is nasty work. The cavacil goes everywhere and it IS SO STICKY. There are sometimes a few changes of gloves during this process. Once in position, I begin to apply the braces. This is tricky and I am rarely perfect in ensuring the fit is perfect. Once all the clamps and braces are in place, I clean up. The whole process is done in a white protective suit with full mask and takes about an hour. After a couple of hours, I pull it all down and clean up my messy spots. here if the final product.
Tomorrow, I will finish the inside!
The title says it all. The day was spent preparing and attaching the ply/formica laminate sheet tot he aft bulkhead. A great deal of time was spent cutting out the window in the laminate. The window allows viewing access to the area beneath the cockpit and especially the steerage. I also routed the teak that serves as the edge of of the wood covering the cockpit. It as a very long day, but I finished what I set out to do. My phone died, so I will provide pictures tomorrow.
Today’s outcome will bring me back tomorrow. If I squint my eyes and only look at what the picture shows, I see the beginnings of what Gemini will be in the near future.
Another day wearing a respirator and working with resin. I finished laminating the aft cabin cabinets with ply/formica.
Here is a close up of what almost all new bulkheads or partitions look like.
Cabin furniture will be laminated with teak.
Tomorrow, I plan to install the face onto the cabinets after I insert the cabinet backings. Stay tuned-it will look amazing.
All I did today was sand all the areas where I fiberglassed. Sanding is necessary to ensure that new fiberglass or resin, if applied, sticks. That may be necessary in places where there are voids or where the wood is not fully protected. Sanding is also necessary to ensure there is a good mechanical bond for the gelcoat to adhere to. I will be applying gelcoat to the entire area in the future. I need to apply the gelcoat before it gets too cold in order for it to cure.
I made a decision that from this point forward, I am only going to focus on the aft berth. Next week, I hope to sand the aft bulkhead then dewax the cabinets where I painted gelcoat sometime late last year. I need to dewax the gelcoat to ensure the laminates stick when they are cabaciled (new verb Websters) in and when I touch up the cabinets with new gelcoat. Next, I am going to apply the laminates to all walls and bulkheads. Making leveled areas in the concave hull with plywood will happen after that. To fasten them in and protect them, I will cover them with resin and or fiberglass. When that is finished, I will put in the middle bulkhead to the aft stateroom. This bulkhead holds up the forward portion of the bunk and hides the batteries from sight. It also ties into the closet. The closet construction is next. Then I will put in the sub-floor between the main wall separating the aft cabin and galley. I give myself three weeks.
I finished fiberglassing the starboard aft bulkhead. Today, I fiberglassed the side where we store the poo. No poo to be stored there in the future. We are going to have a composting head. I also sealed the bulkhead in front of it-the one separating the poo room from the head. There was some prep necessary and that took about an hour of grinding and sanding. Here are both sides. When I’m done, nobody will be able to tell that I scarfed the bulkhead together.
All afternoon I labored making the aft stateroom cabinet laminates. See them laid out and all neatly sanded to fit. There was a lot of back and forth between Gemini and the sanding machine to make this a reality.
Here is what they look like loosely put into the boat.
It was a good day.
Arriving at the marina was like moving into a fogbank. I didn’t know where to start, and there was no spotlight shining on the obvious next step. I have to admit I was also feeling a bit overwhelmed. The number of tasks is thick.
First step, go see the folks in the yard. Quick hello’s and I was off. I eventually found my way.
First, I sanded the foam beneath the most aft starboard bulkhead into a nice crescent shape to allow the fiberglass to sit nicely. Both sides needed the shave. I then jumped in full bore. Anyone watching would know that my donning the Tyvex suit meant some fiberglass had to be ground into control. Somehow, some fibers feel better being as close to me as possible. I finally fiberglassed the aft portion of the bulkhead. Not feeling satisfied, I fiberglassed the hull where JJ and I had pulled up some of the copper mesh. Still feeling incomplete, I fiberglassed the outside of the propane locker.
Lastly, after lunch and a couple of aimless trips back and forth from the shop to Gemini looking for the next step. Maybe, my mask isn’t working and I am resin burned. I felt out of it. I made an attempt to finish removing varnish from one of the doors. I didn’t even try before I decided I was going to start sanding the fiberglass work I did last week. But, that would just get stuck to all the wet resin laying around and crap, it really smells like resin. I finally decided to laminate the interior of the aft cabin storage bins. See the results? I just need to cavacil them into place.
Today, marks the end of rot in our times on Gemini. As you can see, I removed an interesting shape from the bulkhead. Originally, I was just going to remove a little, then I thought that I should remove it all.
Much of the day was spent making the braces that would keep the pieces together at the right angles while I fiberglassed the wall. I had to drill a lot of holes in the braces as well as in the remaining fiberglass tabbing to ensure the wood went into place. Gathering the supplies also took some time. The plan was to wet out the wood with resin to provide a barrier if water got in. Then, I put down cabacil in between the board and the existing tabbing. With all of it wet and sticky and me putting my head through the openning you see in the picture-
I screwed in all the braces.
I was surprised at how sticky I didn’t get. I didn’t even put on the Tyvex suit this time. The final product looks good. I outlined the existing holes prior to covering so that I could drill them out once all the fiberglass was dry.
Wolf was sick today, but hopefully, he feels better tomorrow. Today, I was going to attempt to tackle putting on the ply/formica laminate on the inside of the aft cabin. However, when I arrived-I learned that I needed to put on the most aft piece on the bulkhead. The bulkhead that separates the aft cabin and the aft storage area had some rot in the bottom. The builders did not tab the corner correctly and water drained down the length of what has now been replaced with Wolf’s Wall.
It took me most of the morning to get out the rotten wood.
The afternoon was spent measuring and cutting a replacement.
I was making some last minute alterations to the replacement plywood, when a worker asked if I was leaving. I told him it wasn’t even lunchtime. He told me it was 3:40pm.
Before I left, I filled the recess created by the converging fiberglass tabs that held the rotten wood with cabacil. I also took the opportunity to glue the 1/2 inch foam using the cabacil. The foam acts a cushion for the bulkhead to help reduce the chance of creating a bulge in the hull.