After the success with the A class catamaran, (glass on foam) I was looking for something new to build using the same method. I've been wanting to do another model of one of my full sized boats, so thought the day sailer would be a good subject. Model is 1m long.

Made a sandwich of 4 x 25mm foam sheets on the 5mm ply deck cutout, glued with foam safe contact spray. The area around the cockpit was only glued round the edges, as 2 sheet thicknesses had to be removed later.

The big foam sandwich was shaped by eye with a Surform file when dry, using the laminate lines for reference. The full sized boat had been measured previously, and everything scaled 20%, and lines drawn on the foam as a guide also.

Once I was happy with the shape (checked side to side with cardboard templates) I glassed the hull with epoxy resin and 5 oz cloth. I rolled on a thick layer of resin before the cloth, to help with filling the pores of the foam. Hull had 2 further coats of resin, sanded between coats, then another 2 with fairing powder mixed rolled on, the 2 more thick fairing mixes squeegeed on, (imperfections filled as well). Each coat was sanded back to eventually hide the weave and leave a smooth surface. LOTS of sanding !-orbital sander, finishing sander, block sanding etc and some Surforming of any high spots in the resin.

Next job (yesterday and today) was clamping the hull to the bench for cutting out the cockpit, (clamps go under blocks with cutouts screwed to the bench with a cross bar for the deck, and hull on foam blocks) Cockpit was cut out using a jigsaw with a short medium blade, and finished to the lines by drum sanding and blocking.

The deck and 1st lamination came away as one piece, and the second lamination was cut down to with an extended snapoff knife set to the depth, and then picked out easily in large pieces due to no glue in that area. Cockpit is now 50mm deep, with a nice flat bottom, ready to either epoxy thin ply round or glass it then lay ply. The deck will be glassed eventually as well. Centerboard case top will be routed out to drop a complete case unit through, (as I did with the cat)

Transom is also 5mm ply, epoxied on before glassing, (which links its' edges to the hull, otherwise it would only be a foam strength joint) Next I'll have to knife some epoxy between the laminations on the centerboard case, as they obviously had no glue previously. the whole case will be ply sheeted and braced.

I'll leave painting till last, as the hull will have a lot more done to it yet ) rub rail, coamings etc) This is where it's up to at the moment,- more to follow. See pics of the full size boat, and some of the detail I hope to add to the model. Boat was built in the 80s, took me a year to restore it, (including removing a full width outboard well.)

JB

A bit more progress made since the last post. The hull is now fully faired and ready for paint, which will be done later. The centerboard case now has had the slot routered out for the actual case insert to drop through. The guide for the router was screwed to the deck, which made this job easy.

The c/board case was next closed in with 5mm ply to give it some strength, as the keel will probably need to be quite long and need support top and bottom in the foam core. The case will be epoxied to the floor as well once that is fitted, forming a good brace.

Next, the case was sanded back and edges rounded, then I did a bit of tunnelling under the foredeck to make some space for the winch and RX etc (still have to work out how/where things will fit and how the sheets will work eventually) Floor pattern has been cut and floor will be cut from 2mm ply and epoxied in. Side panels will also be epoxied to the deck and floor to close in the foam.

JB

Floor now epoxied in place, and the centerboard case insert has been epoxied in with 4mm extra top and bottom to be proud of the case and hull bottom. This was so the resin filler wouldn't run into the insert.. Slot in the bottom of the hull was made larger, the top end being a better fit.
The top was taped and the resin was poured in from the bottom, ( taped to make a trough) so it would fill the gap around the insert. It took about 1/2 a cup of resin to seal the insert in place, making it a strong section to take the force from the centerboard. All was sanded off once set. Insert will be sealed with a thin epoxy timber sealer

Hitec winch has been ordered. I'll need it to play with the positioning. Rudder servo should fit in the center under the rear deck.

Previous update below won't move to the trending section for some reason.

JB

Took a bit of thinking about, but eventually figured out where to hide the big Hitec winch. I've tunneled out the foam under the foredeck (access hole cut to allow winch pulley fitting and removal) and epoxied in a 5mm ply plate to screw the winch tray to. Tried the fit yesterday, and it all went according to plan. The winch tray is screwed to the plate (both pre drilled to ensure a proper fit), then the winch is slid down the small ramp, then jiggled into the mount sideways, then secured with the servo screws, (2 front screw driver access holes to be drilled in the deck yet.)

When epoxying in the plate, I screwed the 2 winch tray screws right through the tray, then screwed them a few turns into the plate, so that the tray sat up off the plate so as not to be accidentally glued to it. This allowed me to hold the plate/mount in the correct position till the epoxy set. Once set, the mount could be screwed down fully to the plate.

The main/jib sheet endless hauler will run either side of the c/board case, and drop down on pulleys on the side of the c/board case to be close to the floor, and round a pulley at the stern, (main and jib sheets taken off that as usual.) One of the pulleys will be adjustable for a tensioner. The area under the foredeck will probably also be housing the RX and battery. All this will be closed in later with removable screens.

Also started on some test sails,- made the patterns and cut some from rip stop nylon. My sewing's rubbish, but unfortunately, opaque Mylar is not readily available in large sizes here, only clear,- as that would be much nicer. Still trying to source some. need to find some suitable material for battens, as the sail is quite large (foot is 550mm, and 1200 luff) and is going to be floppy without them.

JB

JB

8mm holes drilled for screwdriver access to winch servo front mounting screws, and cover plate made. Mast step will be on top of the cover.

JB

A bit more progress since last time,- deck has been re framed to add camber and a smidge of sheer, due to the deck looking too flat, unlike the full sized boat. Deck was covered with 1.5mm ply. Cockpit sides and under foredeck have been covered also. (pic 11, showing previously flat deck)

Mast has been completed and sails fitted (jib to be remade with a narrower foot and longer luff) the chainplates were made and temporarily screwed on. Trial fitted the mast yesterday using stainless wire rigging and bowsers (bowsies to boy scouts 😊) made from aluminium. Now starting to look like a yacht. Sails may need remaking at some stage, but they will do for testing, (everything is temporary till working well on the water) would like opaque mylar film, but can't find any here.

Also rolled on a final coat of resin to make sure everything was sealed after all the hours of sanding and fairing. A lot more to go yet, but there's a light at the end of the tunnel (probably the train coming 😀)

JB

Deck now glassed, gunwale strips on, inner cockpit sides and centerboard case insides, coated with epoxy timber preservative. Rudder stock started. Made from laminated and f/glassed 12x12mm spruce, and the slots done on the mill. Still have the blade and gudgeon and pintle to make. Hull is almost ready to throw some paint at.

JB

Side seat slats cut and stained, - rudder stock stained- seat frames made, - rudder blade was made from 3 pieces of 1.5mm ply, cross grain epoxy laminated, and pressed between 2 sheets of glass to keep it flat while setting, (same with the stock). Second coat of varnish drying in the oven, as it's too cold at the moment . First coat of Zinsser primer applied to the hull.

Weather is rubbish at the moment, everything (glass/paint) is taking time to set/dry.

JB

Been doing a lot of painting lately, but it's taking a while due to the weather at the moment, (daily rain and cold) and odd things happening to the paints I'm using, (different companies using different thinners these days in their spray can paints, which are not compatible with like paints from other manufacturers.)

Used to be, you could buy spray enamel for eg from different manufacturers and they'd be fine (most used the same propellants and thinners), - now with all the green nonsense, they all seem to use different products, and some will eat previously painted items. Finally getting somewhere though, after having to re-do some parts from scratch.

Finished the rudder stock/blade/gudgeon and pintle setup, made the comings and trims for the rear deck, transom and c/board case, and am in the process of spraying many coats of varnish on the bits. Hull now has 3 coats of resin, 2 coats of Zinsser sealer, 3 coats of industrial lacquer undercoat, and 2 coats of International PreCote primer, - all sanded back to get as good a finish as possible.

Deck has also been sprayed with the final colour. had to re-do the rear deck trim, as I forgot to notch it for the coamings to flow into and it didn't look right. Won't glue any trims etc in till I'm happy with the varnish.

Also been playing with the winch set-up and positioning the pulleys to drop the mainsheet hauler (runs either side of the c/board case) close to the cockpit floor. Mainsheet will attach to one side, and jib to the other, (that's the plan anyhow🤓) Just trial fitting everything at the moment, -takes time to get things working/fitting well, having to design on the go, - lots of measuring 3 times and cutting 6 🤔💡

JB

Getting closer

Been busy getting everything ready to go on and in the boat. Trims for the coamings, transom, rear deck, c/board case top, varnished and ready to attach (just started with c/board case, transom, and rear deck trim gluing, as we have had a few fine days, painting is slow in 4-15deg C) Seats are assembled but not glued in, as I'm probably making them removable.

Keel weight is cast with a through slot milled for a laminated double 3mmx50mm aluminium keel, and bolted crossways with 2 x5mm bolts with recesses milled in the bottom of the lead to fit them, so the bulb doesn't fall off.
It was then shaped with body filler (now glassed as well).

A slide in 'drawer' for the rudder servo made as well. The cover panels for the foredeck and rudder servo have been made, and being painted, these fit into bottom rails and will be screwed in at the top so things can be accessed.

Sheet hauler has been finished, and seems to work well (a bit complicated but the only way it can be done to keep everything out of the way. The 2 blocks were milled from Formica, with nylon pulleys fitted. Tricky milling the pulley 'legs', as they are only 1mm thick,- took 4 goes to get 2 good ones 😐

A few more things to do yet, (attach rudder and set up, sort jib sheet and make new jib). The last thing will be painting the outside of the hull when I've finished knocking it about.

Short vid of the winch system working.

JB