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Thread: Summer work down at the boatyard and in the workshop

  1. #71
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    Default Re: Summer work down at the boatyard and in the workshop

    The first layer of marine plywood is on the deck beams and glued and screwed down and now has been trimmed with a router and finished off with a plane to square up the edges ready to fit the next layer of marine plywood



    Neatly trimmed round the fore hatch opening and after the second layer is fitted the hatch base philth can be made and dry fitted to take the new hatch and the upstands for the edges inside the opening can be made as well







    The edges of the plywood have now been cleaned up and are ready to be masked up and the cabin side covered again to keep any glue from going on the newly varnished cabin sides.









  2. #72
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    Default Re: Summer work down at the boatyard and in the workshop

    The transom as now come along from being bare wood to being well on its way, now it as four coats of thinned varnish

    Bare wood


    Two coats of varnish


    Now it has four coats of varnish, just another four to go The latest coat was put on by the owner partner

    Finally got a piece of marine plywood that is what it says it is and which is glued together through and through




    While he started to paint out the aft section of the cockpit so the new aft bulkhead can go back in position and start the rebuild of the cockpit floor bearers and cockpit lockers



    Another job that is coming along is the second layer of marine plywood for the fore cabin roof/deck




  3. #73
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    Default Re: Summer work down at the boatyard and in the workshop

    The new replacement marine plywood arrived this lunchtime so we can get on with doing the rest of the main cabin roof/deck after the deck beams are made and the cabin side is repaired where the top edge is rotten



    The first part of the fore cabin roof/deck is now glued down in position and making the larger part fitted to the forward edge and the fore hatch hole is cut out to help glue the edge round the hatch opening is glued down







    Marking out the screw holes for the forward part so it will make it easier when the plywood as the epoxy glue applied to it.





  4. #74
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    Default Re: Summer work down at the boatyard and in the workshop

    She is really getting a good going over! Disheartening that lot of plywood, I hope your supplier didn't give you any trouble.

    I'm a bit curious/concerned the way those sister ribs were installed in the cockpit area. The way they are sistered above and below where the bilge stringer lands, but not at the bilge stringer may create issues in the future. At lease there seems to be minimal bend in the ribs at that point, which is good.

    As always, Nice work! she will be like a new boat when you are done.

    Ohh, ..... curious, ....... that new/replacement plank on the starboard side at the tuck in the bilge, ... is it fastened with machine screws and washers & nuts?

  5. #75
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    Default Re: Summer work down at the boatyard and in the workshop

    Hi Ned,

    The plywood was a bit of a problem, however, it was resolved ASAP by my supplier, who got their supplier to come down and look at the state of the plywood, my supplier took their supplier to task about the poor quality of the marine and the lost of work on my behalf and problems it caused by not having the plywood on time to finish the yacht's decks. The ribs on the other hand were put in by a former owner and does ask the question why it was done in that manner. Yes the yacht is going to left my yard in a far better condition than when arrived although it will not be finished off by me as the owner wishes to do much of the final fitting out himself. The replacement plank is fitted in position in the same way it was fixed in the first place with copper nails and roves through the plank lands and then the bilge stringer will be glued together on the joint with the old piece and it will then be itself nailed in position with copper nails and roves and where the nails go through the rib and not through the land part of the hull will be fitted with a wedge to ensure the plank does spilt along it length.

    Regards

    Simon

  6. #76
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    Default Re: Summer work down at the boatyard and in the workshop

    Hi Ned,

    The plywood was a bit of a problem, however, it was resolved ASAP by my supplier, who got their supplier to come down and look at the state of the plywood, my supplier took their supplier to task about the poor quality of the marine and the lost of work on my behalf and problems it caused by not having the plywood on time to finish the yacht's decks. The ribs on the other hand were put in by a former owner and does ask the question why it was done in that manner. Yes the yacht is going to left my yard in a far better condition than when arrived although it will not be finished off by me as the owner wishes to do much of the final fitting out himself. The replacement plank is fitted in position in the same way it was fixed in the first place with copper nails and roves through the plank lands and then the bilge stringer will be glued together on the joint with the old piece and it will then be itself nailed in position with copper nails and roves and where the nails go through the rib and not through the land part of the hull will be fitted with a wedge to ensure the plank does spilt along it length.

    Regards

    Simon

  7. #77
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    Default Re: Summer work down at the boatyard and in the workshop

    The forward bulkhead will be sorted with new wood being put in place to fix the sole bearers to be fixed too.



    The old aft cockpit sole bearer being used as a datum marker to be able to reference the rest of the cockpit sole bearers







    Part of the old aft bulkhead, using this a reference marker as well







    All the pieces of wood planned up to the correct size to make into the new cockpit sole bearers









    The first piece back in position and now the jigsaw puzzle can start to go back together





  8. #78
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    Default Re: Summer work down at the boatyard and in the workshop

    Nice to sit and watch as a restoration takes place and not have to do the work! Well done. Just an aside. My restoration project still underway was built by JW Shuttlewood & Son of Paglesham in Essex. I believe their yard was destroyed by fire many years ago. Possibly heard of them? Kind regards, Dennis

  9. #79
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    Default Re: Summer work down at the boatyard and in the workshop

    Setting out the old cockpit sole bearers ready to piece together the jigsaw puzzle





    Making the first of the cockpit sole bearers and have been able to use one of the original bearers as it is good condition and able to be reused







    Dry fitting them together so it can be dismantled it need be once it is in the cockpit for final adjustments






    Already to put in the cockpit to fit in position and make any final adjustments.





  10. #80
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    Default Re: Summer work down at the boatyard and in the workshop

    All the hard work by the owner's partner with careful rubbing down between coats has started to make the transom look like it did when the yacht was first launched 45 years ago,



    The owner has been applying a number of coats of white undercoat and is building up the layers and the yacht's hull is now starting to look more like its original self and is going to look beautiful on the water when she goes afloat







    The hull is now starting to look every bit the beautiful yacht she is and in this ownership will enjoy many an enjoyable sailing miles







    Looking beautiful from any angle and something to be proud of with all the hard work put in by the owner and his family









  11. #81
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    Default Re: Summer work down at the boatyard and in the workshop

    The cockpit sole bearers are coming along well with them being fitted in position so the the area can be used to help rebuild the cabin roof/deckhead







    A lot of measuring to get it to fit in position







    Lots of angles to work out and cut to ensure it fit in the correct position







    The first side also in position with just a small amount of trimming to be done






  12. #82
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    Default Re: Summer work down at the boatyard and in the workshop

    In order to get the correct measurements the engine bed was bolted down into position to set up the position of the gearbox drive shaft coupling



    Once that was done the propeller shaft with the drive coupling fixed to the forward end of the propeller shaft was inserted until the coupling was in the correct position and the stern tube and the shaft were able to be marked off






    The engine is having a flexible coupling fitted to take out the shock loading of the gearbox going in and out of gear and making the transmission smoother







    Just sliding the cutlass outer bearing on to the shaft to gauge how much of the stern tube as to be removed and threaded







    All removed and marked up and ready to go back to the engineering workshop to be machined up so that the next time these parts are in the workshop they will be fitted back in the stern post.





  13. #83
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    Default Re: Summer work down at the boatyard and in the workshop

    First job is to cut a number of wedges to see which size fits between the back of the rib and the face of the plank


    The space under the rib where the nail goes through is where the wedge as to go in order for the plank not to spilt



    Here is a wedge in place ready for the nail to go through



    Full wedges that need to be cut down to length and thickness



    All the wedges in position and ready for the bilge stringer to go into position



    The bilge stringer now nailed down in position


  14. #84
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    Default Re: Summer work down at the boatyard and in the workshop

    Thank you for posting these pictures. It is fun to watch the restoration.

  15. #85
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    Default Re: Summer work down at the boatyard and in the workshop

    First job is to cut a number of wedges to see which size fits between the back of the rib and the face of the plank






    The space under the rib where the nail goes through is where the wedge as to go in order for the plank not to spilt








    Here is a wedge in place ready for the nail to go through








    Full wedges that need to be cut down to length and thickness








    All the wedges in position and ready for the bilge stringer to go into position








    The bilge stringer now nailed down in position





  16. #86
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    Default Re: Summer work down at the boatyard and in the workshop

    The last but one coat of varnish on the transom, which with every coat is looking more beautiful



    The hull now as had its final coat of undercoat and the bottom as had its final coat of underwater primer













    The keel as had a coat of Epoxy VC Tar primer to give protect to the keel.





  17. #87
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    Default Re: Summer work down at the boatyard and in the workshop

    Now the supports for the floor sole bears are in position the whole of the cockpit floor feels all together safer and the working height for doing the cabin roof repairs is at a height that can be worked at safely.



    Now just got to screw the temporary panels in position and will be able to get on with the repairs to the cabin roof beams





  18. #88
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    Default Re: Summer work down at the boatyard and in the workshop

    The first job in the reconstruction of the cabin roof is the cutting out of the rotten top section of the cabin side. This was done by use of a sonic saw and a batten fixed to the cabin side at the bottom edge of the rot and cut along the top edge of the batten cutting a straight line along from aft to forward.



    Having cut the rotten area out, patterned up a new piece of mahogany to fit in the space and clamped it down into position









    It also needed clamping side wards as well as the cabin side has a 9 mm bend in it from forward to aft, Once it was drilled and glued and screwed into position then it was time to sort out the rest of the parts that make up the cabin side and roof.



    The cabin roof beams that are in bits and a small jigsaw puzzle which will have to be remade to finish off the deck beams and so the plywood can be laid over the new deck beams once they are made and fitted





    The deck beams set out on the new bit of mahogany ready to be cut on Monday morning and when planed up fixed in position and when the other deck beams are made the plywood can be laid over the beams





  19. #89
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    Default Re: Summer work down at the boatyard and in the workshop

    Using the old roof/ deck beam as a pattern



    Marked it off on the plank of hardwood, it shows how much curve there is in the beam camber







    Cut out of the plank of hardwood and now ready to cut near to the scribe marks and so it can be plane to the correct shape ready to plane down to thickness and fit in position on the repaired cabin side







  20. #90
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    Default Re: Summer work down at the boatyard and in the workshop

    Having repaired the cabin side it was time to shape and glue the beam shelf to inside face of the cabin side



    Having glued and screwed the beam shelf in position and the glue cured off it was time to shape the top of the cabin side and beam shelf to the rest of the cabin









    Finally finished the top of the beam shelf and cabin side







    It is time to make the deck beam and once shaped and the ends cut to fit the beam shelf it will be time to fit the other smaller beams and then the plywood top for the cabin roof/deck and once done sheath the deck

  21. #91
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    Default Re: Summer work down at the boatyard and in the workshop

    The best way of making deck sheathing pieces is to make them out of brown paper as it lays on the deck in much the same way as the material.



    Now that the patterns are made it is just a matter of taking the patterns and laying them out on the sheathing material and cutting round and then applying the resin to the deck and then putting the matting on the resin and then applying more resin until the matting is fully covered







    The patterns for one side of the yacht should be able to be used for the other side with a small amount of adjustment in a few places.





  22. #92
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    Default Re: Summer work down at the boatyard and in the workshop

    Cutting the joints on both ends of the first fore and aft hatchway beam





    Both the hatchway beams in position and now it is the turn of the first of the short beams to be cut and fitted in position









  23. #93
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    Default Re: Summer work down at the boatyard and in the workshop

    After making good the cabin side where it was rotten



    The first of the deck beams was being fitted







    Then the two fore and aft hatchway beams







    Then it was time to fit the short half beams before setting out the area to be covered







    The first layer of plywood glued and screwed down in position, now just letting the glue cure off and then router the edges before setting up to put the second layer of plywood on the first layer. Once this is done the outer edges will have a radius put on the edges and the decks will be sheathed with epoxy and matting





  24. #94
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    Default Re: Summer work down at the boatyard and in the workshop

    Dry fitting the second layer over the first layer and marking the beam positions on the cabin sides before transferring them to the second layer of plywood

    The second layer is laid over the first only after the first layer as been trimmed with a router and then planed at the correct angle to the cabin sides

    The first two sections of plywood being clamped down into position so that the marks for the position of the beams can be transferred to the top layer of plywood so that the screw holes can be drilled through the plywood before fixing the plywood down on the first layer with epoxy glue.

  25. #95
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    Default Re: Summer work down at the boatyard and in the workshop

    The complete second layer glued and screwed down



    The screw holes starting to be filled ready to be sanded down ready for the whole area being sanded before the plywood is covered with sheathing material







    The edges have to be trimmed back and then a radius put on the edge so the material will laid over the edge.











  26. #96
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    Default Re: Summer work down at the boatyard and in the workshop

    The masking tape from the hull has been removed and the hull is re-masked up with brown spraying paper to protect the painted hull from any excess glue that comes off the deck sheathing


    Well masked up, now have to router the edge of the deck with a radius bit to put a radius on the edge of the deck so that the sheathing material lays over the edge of the deck





    The same treatment across the transom to protect that beautiful varnished transom



    Once the cabin roof/deck as been trimmed the same treatment will be done to the cabin sides


  27. #97
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    Default Re: Summer work down at the boatyard and in the workshop

    Following the re-decking part of this job with great interest as I think that I'm going to have to do the same on my 4 Tonner. Is it 6mm or 9mm ply that you are using in each layer ?
    Nick

  28. #98
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    Default Re: Summer work down at the boatyard and in the workshop

    The outside edges of the main cabin deck is now planed flush with the cabin sides and just the radius to be put on with a router when the team are back in the workshop.

    The new door trims are getting made so the when the repairs are done to the main cabin bulkhead at the base of the door way these new trims can be fixed and glued into position

    Marking out the door threshold piece to fit on top of the repaired cabin bulkhead

  29. #99
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    Default Re: Summer work down at the boatyard and in the workshop

    Hi Nick,
    The Re-decking of this finesse 24 as been done using to sheets of 6 mm marine plywood glued and screw together. The first layer glued and screwed to the deck beams and gunwales and carlins and then the second layer was fitted on to the first layer with epoxy glue and screwed through the first layer on to the deck beams as well. so making a 12 mm deck without the stress of bending a 12 mm piece of marine plywood over the curves. All the joints between the plywood were at least 12 inches apart so as to cut down at leaks between the layer of plywood. It has made for a extremely strong deck which is going to be sheath with matting and epoxy to make is stronger still.

    Regards

    Simon

  30. #100
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    Default Re: Summer work down at the boatyard and in the workshop

    Quote Originally Posted by jstarboats View Post
    Hi Nick,
    The Re-decking of this finesse 24 as been done using to sheets of 6 mm marine plywood glued and screw together. The first layer glued and screwed to the deck beams and gunwales and carlins and then the second layer was fitted on to the first layer with epoxy glue and screwed through the first layer on to the deck beams as well. so making a 12 mm deck without the stress of bending a 12 mm piece of marine plywood over the curves. All the joints between the plywood were at least 12 inches apart so as to cut down at leaks between the layer of plywood. It has made for a extremely strong deck which is going to be sheath with matting and epoxy to make is stronger still.

    Regards

    Simon
    Thanks Simon. Looking good !
    Nick

  31. #101
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    Default Re: Summer work down at the boatyard and in the workshop

    Last Monday my new apprentice started working for my company and he has fitted in well to the way we work and is a quick learner when it comes to making new panels to go into the yacht. After a morning of showing him around the yard and the workshop and showing him where all the equipment and tools are stored and put away everyday.


    It was down to work, the first job was to clean up the workshop so that he could see that in order to work effectively and in a safe manner the workshop has to be kept clean and tidy and clear of any hazards. One of the major rules of any workshop, keep the work area clean and tidy.


    After that job was done the apprentice was given a bulkhead panel to replace which is a simple job for an experienced boat builder is a daunting job for s new apprentice. However with the correct instructions the apprentice can and did get on with the job well and by the end of the day was ready to mark the template out and cut the new bulkhead panel the next morning.


    However, that did not happen as I was admitted into hospital for a week with cellulitis. This has taken me off my feet and will continue to keep me off my feet for the next week, however with my new apprentice doing most of the heavy work and I can direct him to do most of work I would otherwise do. So although the work will be done it will be done at a slower rate, but it will be done.


    So Monday the team will start again and will be interviewing a second apprentice to help get the work done and to be able to quote for more work over the coming months. Hopefully the second apprentice will work out as well as the first apprentice and then the work around the workshop and the yard can be got through and some of the projects that have been on the back burner for a while can be re-started and can start to make a few new dinghies out of both wood and small glassfibre dinghies for the new sailing season in the spring. Also tidy up the yard and make things more accessible.


  32. #102
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    Default Re: Summer work down at the boatyard and in the workshop

    However, that did not happen as I was admitted into hospital for a week with cellulitis. This has taken me off my feet and will continue to keep me off my feet for the next week,

    Now that is painfull, as I've learnt. Must have been bad for a week in the quack house.

    Nick

  33. #103
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    Default Re: Summer work down at the boatyard and in the workshop

    Today, being my first day which i did not feel under the weather, I was able to get a number of jobs done and other underway on the Finesse 24. Was able to cut the lengths of wood for the trims for the edge of the upper and lower deck edges and start to get the rubbing stake backs cleaned up and get rid of the old sealant and bits of rotten planking and deck that came off when the decks were removed


    Have two young people working .work under my supervisor the jobs were got underway and, just need finishing off before they get on to the next jobs on the yacht.


    The next job on the yacht that as to be done is to plane the top and bottom of the trims to the angle of the deck. so when they are fitted they sit well along the cabin side and on the deck to make a good seal between an area that moves while the yacht is underway in a seaway. Another job to do tomorrow is to radius the outside edge of the lower deck and sort out the top of the transom so that the whole of the deck is going to be ready to get painted at the weekend.


    One job that as to be done tomorrow or and Thursday is to harden up the nails on the ribs in the main cabin between the toilet compartment and the cockpit bulkhead so that the plank will give less time to take up when she goes back afloat. While this is getting done the main hatchway surround and trim will be refitted and the sliding hatch will be re-instated and the new fore hatch philth will be made to take the new hatch. So all in all a busy few days ahead for me and my new apprentices.

  34. #104
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    Default Re: Summer work down at the boatyard and in the workshop

    The first coat of the protective epoxy primer to the decks and all the edges around all the decks



    A major change of colour and looks like a different yacht, just have to let it cure off for 5 hrs and then paint the second coat on to the first coat and the job of sealing the decks will be done and then the trims can be fitted and sealed down with marine sealant.





















  35. #105
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    Default Re: Summer work down at the boatyard and in the workshop

    One of the apprentices doing the hardening up of the nails after being instructed how to do the job.







    The cockpit sole floor bearers now fitted in place and the front beam bolted and screwed in position and once the area is cleared of the temporary floor boards and the vac the templates will be made and the new floor boards will be made.







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