Projects to keep me off the streets - Fire Department Table, Kayak
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TAPING THE STARBOARD INSIDE SEAM
One side done, but this is the part of the job that makes Bishops kick out stained glass windows. It went well though. Let this side set up, then tomorrow flip it over onto other side to do port side inside seam.
Bias cut strips of fibreglass, rolled up and soaked in epoxy then rolled out along inside seam with a brush on a stick.
aft
forward
The camera worked well, but it's kind of like being an elephant gynecologist.
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Got port side seam done tonight. Thankful this is over. Both the boat and I are well epoxied.
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So long as you're not expoxied into the boat, I think there's hope.
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farback.ca/index.php/kayak-five-das-boot-current-build-being-completed
6JAN17
Lots of sanding, and a bit of leveling with the spoke shave, and the outside hull is ready to go. Tomorrow a bit of sanding dust and epoxy mix to fill in some gaps, then outside fiberglass tape seam. It's carefully masked up, and when the outside glass gets to the 'plastic' stage I'll cut at the tape lines and remove the tape to get a clean edge. This edge will be sanded in to disappear, then entire outside gets light sanding, touch-ups and a final layer of epoxy.
Making sure I don't get epoxy into the fittings for the deck lines.
If I was a 20 year old knob with a front wheel drive 4 cylinder rice burner with an air foil, I could just call these race stripes.
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Table and Kayak look great!2
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farback.ca/index.php/kayak-five-das-boot-current-build-being-completed
7JAN17
Taped the seams this morning with continuous 18' x 2" strips of fiberglass. Rolling these up was NOT a good idea, loose threads snagged up as it unrolled, making it one hell of a task. Fiberglass and epoxy is like a mean dog, it can smell fear so you just got to carry on.
I went to the gym, ran errands etc. while this set up for a few hours so I could cut a clean edge and remove the tape.
I made the interior bulkheads out of minicell foam. These are cut to fit tightly at form stations 6 and 11, forward of the foot braces, and aft of the cockpit.
Fitted and placed the aft bulkhead.
Sanded, trimmed up and epoxy coat to clean up cockpit and coaming rim.
Next on to sanding, last epoxy layer, fit and finish on end stems, then varnish coats begin.
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8JAN17
Sanding and epoxy work today. Cleaned up drops of epoxy on the deck, masked the edge, then turned over to work on the hull, Sanded and final coat of epoxy for the hull. Can't progress any more today till this cures up.
Before sanding and final epoxy layer.
Got this Jason Bourne look alike to sand the hull to 320.
Results after a couple hours work.
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Later, that same day...
hung up to let bottom cure but allow deck access to remove masking tape.
A wee slip with the exacto knife leads to a visit to the boat shop medical clinic. No time to bleed, work to be done.
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Wonderful progress, beautiful boat! Good timing on the exacto cut, too - much easier to get blood off the project when you're past the raw wood stage. (Hope it wasn't major!)
(One of my best hobbies ever was stained glass; so many wonderful opportunities, especially for an indoor, at-home hobby: The cuts from razor-edge glass-breaks cut painlessly but deeply, so you've bled all over creation before you notice; the fresh wounds invariably come in contact with lead; and you get to breathe lead-solder fumes on top of that. Hard to beat that with most hobbies you do sitting on a chair. ).
The 'yak is looking great!2 -
I've yet to do a major project where I don't end up with some kind of minor injury. Bleeding during surface prep isn't a good thing though. Hopefully, you didn't get any gack into the incision?2
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Take care of yourself.2
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All good. Deep cut, but didn't feel it needed a stitch. Bled like a pig because of the damn heart drugs. It is good the wood is sealed now, it can make a real mess. Cleaned it up and it looks fine today.3
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9JAN17
Hours of sanding. Cleaned up drips on deck from hull epoxy job, then sanded entire deck to 220 to prep for final epoxy coat to deck. Had a fire call in the middle of this, and was away for an hour driving a big red truck to a chimney fire. Masked hull completely to prevent drips, and it's ready to epoxy the deck. It's late here, so tomorrow night for that.
Deck sanded to 220.
Deck sanded to 220.
complete masking of hull
"Where's the stuff from my baking drawer?" she says. "I don't know, I'm a firefighter, not a detective."
complete masking of hull
Ready to epoxy deck.
Cut from last night opened up twice, once while working on the boat and while driving the firetruck. One of our paramedic members fixed me up with some steri-strips. Finally got the hull breach sealed up good.
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Cool progress.
'Sending wishes for happy healing.
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farback.ca/index.php/kayak-five-das-boot-current-build-being-completed
10JAN17
Tuesday night in the boat shop.
Finish coat of epoxy on the deck, prepping for some fittings work tomorrow night to give epoxy a day or two to harden up before starting on varnish coats.
Final coat of epoxy on the deck
Fittings for tomorrow, bungie retainers for seatback, tubing for bow and stern through-holes for carry ropes.
Materials for deck, rope for deck lines and bungie cord fore and aft of cockpit
Carbon fiber seat and seat back.
Modifying seat retaining webbing to work with hip plates.
Shop materials
Makes a neat cut with burned ends.
New system with adjustable fittings.
This how the deck lines and bungie cord will lay out.
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11JAN17
Spent a couple hours on small details while the epoxy coats harden up.
Installed the CF clips that will retain the two lengths of small diameter bungee to hold the seatback to the upper and lower deck just forward of the rear bulkhead. Four of these, two above and two below. Drilled the bow and stern with a 5/8" hole for the plastic pipe liners for the carry handles. These holes are through the areas where the thickened epoxy was poured earlier. Sanded and touched up bow and stern stems and new through-holes for handles, epoxied.
Up at 05:30 to remove tape and plastic from hull before epoxy got set too much.
Magical stuff to hold components in place (CF clips, handle inserts) followed up by epoxy.
One of the four CF clips for the seatback bungees.
Front and rear rope carry handle holes.
Ready for varnish soon.
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You know I think I have never seen a kayak in real life. We did some canoeing as kids.
From what I gather, your kayak is essentially complete. What happens next?0 -
Several Finish coats of varnish for uv protection of the epoxy, fit forward bulkhead and seat, rig deck lines and bungee lines, wait impatiently for spring3
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12JAN17
Short shift in the boat shop.
Couple hours work installing forward bulkhead and rigging seat back, prepping hanging system for varnish process. Ropes rigged so all external surfaces accessible.
Hanging system for being able to varnish without cradles in the way.
The advantage of being a rope rescue tech is knowing lots of tricks with rope.
Shaping forward bulkhead with automotive surfacer. Tapered fit.
Forward bulkhead in place.
Rigged connections for seat back. Seat will be set permanently later when I can actually fit test the position.
Adapted rigging to attach to the hip plates.
Light bungee cords (through last nights CF clips) tension the seat back from the bottom and top
The ancient mariner will go here once the water stops being solid.
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$&*#^ solid water, anyway. I don't mind winter, except for heating bills and crunchy rivers.3
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13JAN17
Several hours work, final (did I say final) sanding of complete exterior before first of three varnish coats.
Sanded, then washed, let dry, final rub down with tack cloth before varnishing.
Varnishing is tricky business. You need to apply lightly, don't let it drip or drool, and keep moving before the 'wet edge' starts to dry up. I use the method explained by the guru of boat building, Nick Schlade.
http://www.guillemot-kayaks.com/guillemot/blog/admin/getting_smooth_dripfree_varnish_finish
first varnish coat
first varnish coat
my trusty Dewalt ROS is starting to fail. It has hundreds of hours on it now.
All the other boys have one of these. They're making fun of me on the kayak builder discussion boards.
I'm sure SWMBO would want me to have one of these.
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I have the same DeWalt random orbital sander...
Your kayak is looking smooth and slick... wonderful!!2 -
14JAN17
Couple hours planning and designing another project, and a hour or so on the boat prepping and applying the second varnish coat.
Prep surface with scotch-bright pad for grip and tack cloth clean
Filtered varnish and 4" foam brush
Second varnish coat applied.
The finish is much deeper than the guy who built the boat.
One more varnish coat to go, the deck lines and seat install and this project will be wrapped up. So... for my next trick I'm building SWMBO two bedroom end tables. We've just had hardwood floor installed, and the painters and cabinet guy for the new wall to wall closet module happen in the next few weeks. SWMBO considered buying these,
but they're just press board crap at $200 each. I can make them from oak at 1/4 of the cost, I have a supply of rough-cut I can mill to size, and the pine for the drawer boxes and hardware won't cost much. This has the additional benefit of keeping me away from the main floor where the civilized folks what isn't covered in sawdust mill about.
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A buddy of mine in Colorado retired (high school teacher) and has taken to building cabinets, furniture and making wooden signs using a CNC router. He is having fun and the furniture will end up being heirlooms unlike most of today's IKEA specials...
Maybe I should consider woodworking as a second career? It does look like fun!
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That table shows some pride in your craft, and is a great project. The kayak is completely awesome!
Though I haven't really done a lot of it, I enjoy working with wood. For a period I did boat/yacht work including some work on white boats. I always enjoyed learning from the real wood working masters in the trade. But I've also worked a decent bit in automotive and other finishing, so what I lacked in the woodworking skills to build certain things I could somewhat overcome in the finishing.
Even on the large yachts, it becomes very apparent how few straight lines exist in any type of boat. I'm sure on that kayak they really don't even exist at all!3 -
The only straight line for this baby will be straight to Kejimkujic National Park for a solo week in the back country the week I retire in June.4
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15JAN17
Third and final coat of varnish applied.
The view from the cockpit.
Three coats of varnish makes a nice deep finish.
Full speed ahead Mr. Sawfish!
Six different woods in this boat.
Eastern White Cedar
Western Red Cedar
Basswood
Walnut
Purpleheart
Ebony
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Have you done your final weigh-in yet? What do you figure it will be?
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https://youtu.be/gd5yB9Vmd6I
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