Wednesday, 13 June 2007
Sunday, 3 June 2007
You can tell I'm feeling a lot more confident too!
Next job is a paddle to replace this old 3.5lb fibreglass one...
Also done by now is varnishing:
- The serious blushing was washed off with WEST water based cleaner and a lot of scrubbing.
- The lots of sanding: smoothing off the edges of the hull to deck joining strips and flattening and providing a key over the whole surfac for the varnish.
- Then 4 coats of System Three WR=LPU varnish, all with the hardener added for extra toughness. This went on OK with a brush, but was very atmospere dependent. The coats in the cooler morning were great, but by the last coat it was wamer and it dried a bit fast, before fully flattening out. My original plan was to then sand back and polish for an ultimate finish so his didn't really bother me, but I ran out of time before the paddling trip . I might still do that in future, but for now it looks OK without. Definitely a 5 metre finish though!
- Two very narrow strips - about 3/4" and 1" wide - reinforce the outside of the upstand to hull joint and run most of the way up the upstand.
- Two similar but slightly wider strips reinforce the outside of the upstand to lip joint, and cove the bottom of the lip. Leave these sticking out past the lip until nearly set, then trim back, but still leave sticking out 1mm.
- Two much wider strips cover the whole of the top of the lip, inside of the upstand and run round to under the deck. At the outside of the rim these meet with the reinforcement on the bottom of the rim to form a strong fibreglass edge.
- Note - before glueing the rim in place I'd sanded down the edge so it tapered to about 1mm thick only, to end up with sharper edge to grip the spraydeck and so that the top and bottom fibreglass layers could be made to meet and reinforce the very edge.
- All the material is 4mm ply, the same as the rest of the kayak.
- The lid turns just 45 degrees to screw up.
- The lid is the circle cut from the deck, to the bottom of which is glued a smaller diameter 'spacer' circle, to the bottom of which again is glued the 'castellated circle' with the four sticking out sectors for engaging with the 4 sticking in sectors on the hatch lip. Glueing this up is actuall the final step in the contruction - see later.
- These sticking out sectors on the lid and sticking in sectors on the lip are sanded to have 'ramps' where they first engage, to provide the 'screwing down' action.
- Do think about how long the ramps should be though: if the ramp is full length along the sector, with the sector at 0mm thick at one end and the full 4mm thick at the other end, then screwing the lid on 1/8 turn unil the sectors are fully ovelapping each other only pulls the lid down half as far as if the ramps only extend along the first third of the sector, with the remaining 2/3 being the full 4mm thick. Either would work, but would need different spacing to end up with the hatch lid flush to the deck.
- It is not obvious in the picture, but one sector in the lid and cut out in the lip is bigger than the others to ensure the lid only fits in one orientation.
- Also invisible on the underside of a sticking in sector on the lip is a small wooden 'stop' to limit the rotation of the lid. These two points mean the lid always ends up with the grain matching how it was cut from the deck.
- The lip is also construted from 4mm ply, with a ring under the deck of the same inside diameter as the hole in the deck (pretty much invisible in the picture.
- Under that is another ring with a smaller inside diameter. This forms the bottom of the channel into which the hatch gasket will late be stuck to fom the seal. I should have chosen a better bit of wood for this - a blackene knot is clearly visible bottom left. I planned to paint it when I chose the wood.
- On top of this is the inner 'inside castellated ring' which mates with the lid. Again, I should have chosen better wood, with a defect visible just to the ight of the hatch lid in the picture. (Scrimping on materials in an unfortunate habit of mine I must break!)
- Everything is epoxy coated and bonded. The final step, after the lip was fully installed, was bonding the hatch lid together. The hole in the middle of the lid is there as I first screwed the layers of the lid together from below, into the wooden handle on top (visible in late pics). This was without glue, and allowed me to fine tune the thickness of the invisible disk between the lid and the 'castellated circle' bottom piece. Tuning this, and careful sanding of the engaging sectors, allowed me to get the lid to end up absolutely flush with the deck with the required level of tightness or looseness of the lid when full screwed on.
- A note on tightness vs looseness: after experiments I ended up with the lid just very slightly loose and rattly when fully screwed on, and relied on the pressure of the gasket to make it a tight fit which would not wok loose. It's worked well so far.
- You can't see in the picture, but one side of the mating sector is covered in epoxy mixed with carbon powder for smooth sliding.
I haven't been using the kayak for long, so only time will tell whether this poves to be a good design or whether sand gets embedded in the threads and causes trouble.
The other hatches have very similar lips, with the channel for a sealing strip, just without the sticking in 'screw hread sectors'.
The other hatch lids are just the cut outs from the deck with 1/4" ply cross ribs standing up near the front and back. These ribs serve two purposes.
- Holding the lid to the required shape. This is flat for the rear hatch, but curve for the front hatch.
- having hooks on the end to accept the elastic hold-downs.
The rear hatch was very easy to make. The deck is flat, so the whole hatch rim can be assembled off the kayak and glued in place fully formed. The hatch lid stays nice and flat when cut from the deck, so the two cross ribs have flat tops - easy.
The front hatch was harder. Recall that the plywood at this point is rather tortured (bent to a shape it doesn't really want to adopt). This shape is only formed when the deck is attached to the hull - which was why I had attached it before cutting the hatches. But, cutting a hole for the hatch will change the stresses in both the remaining deck and the hatch lid, so both will change shape and the lid will no longer match the hole. But the lid matching the hole is the whole point of flush wooden hatches. The following scheme worked very well, starting with the deck already attached to the hull, fully glassed etc.
- Mark out the location of the front hatch (on masking tape on the deck)
- Mark out 4 lines across the deck: two inside the hatch, a little (1"?) in from the front an back of the hatch, and two outside the hatch, about 1/2" infront of and behind the hatch.
- The two lines inside the hatch mark where the under hatch ribs will be, the two outside mark where under deck ribs will be. These will run the full width of the kyak.
- These ribs under the deck and the hatch will hold each in the exact shape they are in now before the hatch is cut, so they will match.
- Make cardboard templates of the curve of the deck along each line. You'll end up with four cardboard templates each with a slightly different curve. Mark them so you know which is which!
- Cut a rib from 1/4" ply to match each template. Mine were about 1" deep in the middle for the hatch ribs, and 1.5" deep for the under deck ribs. The under deck ribs are longer since they run right from side to side of the kayak. The under hatch ribs are as long as they can be while fitting in the hatch rim. My rim has a 10mm wide channel for the seal then a 10mm wide wooden ledge for the hatch lid to sit on, so the ribs have to end 20mm away from each side of the hatch.
- Cut the hatch lid from the deck. (Both deck and hatch lid do indeed change shape as predicted - I've not been doing this work in vain - hurrah!)
- Glue the ribs into place under deck an under hatch lid.
- Fabricate the hatch lip in situ: First glue on the ring around the opening, then the channel bottom piece then the 10mm wide ledge piece. Lots of clamps. This could not be made off the kayak and added in one piece later as the rear hatch lip was owing to the complex curve of the deck.
- Try the hatch lid in place. Breathe sigh of satisfaction that it lines up to within about 0.5mm height-wise all round the edge.
That's more than I expected to write about hatches, but they did take up a bunch of time and thought. If I wanted flush wooden hatches I would do exactly the same again next time for front and rear hatches - unless I got tempted to try magnetic hold-downs - but I'd need to do some more research / thinking about how to let the magnets into the hatch lids before trying that. I won't do another screw wooden hatch until enough time has passed to test the current one thoroughly, just because of the extra time involved.
[Sorry about the mixed units above, it's just the way I think. MM make sense to me much better than inches up to about 1/2", then inches are better!]
Saturday, 2 June 2007
- The front hatch lip is made and just waiting a sealing strip in the channel.
- The wooden screw in day hatch has been made and is also just waiting its sealing strip.
- The rear hatch is still a hole in the deck - although the hatch lip has actually been made off the kayak and is waiting to be glued in place.
- The cockpit coaming upstand has been fitted.
- What sort of fittings for deck lines and bungees.
- Whether to have hatches, and what sort of hatch lids.
- What order to do the build in.
Constructing the deck and fitings was made more complicated by the warped plywood deck of the Point Bennett. It is a very simple and neat design, but the plywood is being forced into a shape it doesn't really want to be in, and the final shape is only determined when the deck is forced onto the hull. In theory it must be possible to prop the deck up while off the hull in the right shape - and this is what Duane suggests doing. However, I decided that I wanted flush fitting wooden hatches, and felt that the deck would have to be in *precisely* the right final shape when building them so they ended up flush - and that could only be done with the deck on the hull.
Why did I want flush wooden hatches?
- Despite Duane's own kayaks being painted and looking fantastic, and despite deciding I would paint mine when I started, by this point I was starting to like the look of the wood and had decided to varnish my kayak instead, and I decided a flush hatch would complement that best.
- The commercial hatches seemed very heavy, and I really wanted light weight: if the kayak was too heavy to be fun to carry down to the sea on my own it would not get used, which would defeat the whole purpose of the build.
So, I'd arrived at needing to attach the deck to the hull before making the hatches. The next consideration was attaching the deck to the hull. The deck was glassed underneath already, while off the hull, and while propped to vaguely the right shape. For neatness I reckoned I could do without a separate glass tape around the join - instead I could attach the deck to the hull next, and then cover the deck and do the deck to hull joint with a single piece of glasscloth. This sounded like a fine plan. But what about fittings for deck lines and bungees?
Screwed on fittings which look to be used on Duane's Point Bennetts look great on a painted hull, but wouldn't suit a varnished one I decided. After research and playing around with various recessed options I came across 'Maroske' fittings, which I decided were the answer.
These are described as best being constructed in situ, before the deck is attached. But I wanted to attach the deck before glassing the outside, and that would mean glassing over the fittings. Cutting the fibreglass off the holes later would be fine, but I could imagine the 'U's filling up with resin during the process, which would not be good! So I decided to construct the fittings on scraps of ply, off the boat. The picture shows a string of them under contruction, with others already done beside them.
- More threads crossing the keel line (cos some of the fore and aft ones do as well a all of the side to side ones) and so more strength and probably abrasion resistance.
- It is easier to mold the cloth to shape at the ends with it on a diagonal.
- Add reasonable sized fillets between the stations (can't take them out yet, they are defining the shape of the hull). This is seen above, with masking tape each side of the fillets for neatness. The fillets are epoxy mixed with WEST filleting blend.
- Remove the satations and fill in the gaps in the fillets.
- Glass the inside.
This worked, and held the shape perfectly, but was more stages and so more work than glassing the outside first.
- A ladder formed the bacic building table. Since the shape is formed by he panels and the stations, there is no need to hold a load of stations solidly lined up with each other, so no need for a rigid strongback. The ladder is beidy, and it's fine.
- lots of intenal stations help form the shape of the hull. These are essential. They are as specified in the design.
- Aligned with two of the stations I made external 'cradle' foms. The cut outs were simply the same shape as the internal forms + the thickness of the plywood. These worked very well and were the main place for the kayak to sit through most of the construction. At times the panels were wired onto these external forms to hold them into shape.
- Stitch and glue, so materials readily available (good, light, know free wood such as Western Red Cedar is not avaiable from most local timber merchats in the UK)
- Designed for the correct bodyweight and size (I'm over 6' but relatively light for my height at 75kg / 11 stone 11 / 165lbs)
- Short enough to fit in my garage which was designed for a 1930's car and is less than 18' long.
- Good tracking.
- A pleasing shape, with upswept ends and raked bow and stern (raked bow but plumb stern as seen on some models didn't appeal).
- Availavl right there, and free!