Now the Chine rubbing strakes are fitted, dry and filled and I have attended to the minor lumps and bumps the next job is to give another coat of resin, taking the issues of the first application into account I intend to apply a thin coat, this has the effect of filling in the pattern of the glass cloth.
Another two days have passed and it’s time to do some rubbing down. I have found that the surface is very hard, more so than I recall some of the other fibre glass projects I have done but these have been using Polyester resin. it’s a first for epoxy, so is epoxy a better choice than Polyester? According to my mini research –


 Epoxy is more versatile
 Epoxy has fewer fumes
 Epoxy is stronger
 Epoxy shrinks less

Conclusion
Epoxy is the better choice for repairing/covering either wooden hulls or repairing fiberglass boats. it has excellent adhesive qualities, wets out fiberglass fabrics and it is tough. it has great thin film cure characteristics, cures in cool temperatures.
After the first coat I wasn’t 100 % happy with the finish but I just thought that some dust had landed on the surface before the resin had dried, (this was proved not to be dust but because of the matting pattern still been visible it disguised the real problem) however this was easily sanded out with wet & dry. Now the hull and deck were looking really smooth with very little sign of the matting pattern it was time to give a final coat. I had decided to coat both the deck and the hull in one go so I mixed enough resin to do the lot. Starting with the deck I started to apply the resin but to may horror it started to pin prick all over the deck surface, panic, panic what was causing this? So was it the brush which I had previously washed out with cellulose thinners after applying the last batch of resin. I decided to remove the resin and use a new brush (I had 90 mins cure time to do this) so cleaning of with paper towel and finally with a wipe with thinners I started to apply resin again – but it happened again as I sat in despair I looked into the pot of resin wondering where to go next when I saw a film on the top of the remaining resin it was then I noticed a ridge in the cups side. it was the wax coating that had melted into the resin and subsequently appeared as pin pricks in the newly applied surface. At this realisation I removed all the resin again and took a breather hoping I had found the problem.
Another day and a light rub down of the deck to make sure the surface is ready to receive its final coat. Resin weighed (in a glass container this time) and well mixed I started to apply again and fortunately it was OK and all surfaces were coated.

Theoretically this should be a very straight forward process and a change from rubbing down the hull so let’s look at the instructions – what instructions! First of all fit some thin card to the sides of the cabin walls to allow for a clearance fit (cornflakes packet) then some minor trimming of the spars to give an exact ,(not tight) fit across the side supports, I decided to pin each of the parts together as well as epoxy in the joints. I always find the best approach is to use a jig to drill pilot holes for the pins ensuring that the pins do not split the wood and the construction is accurate. The frame is then glued up and placed back in the boat and left to dry next job is to fit the corner strengthening pieces, the easiest way I found was to put a card support for the corners to rest on whilst they set still in the cabin structure. Looking forward I had decided to retain the cabin lids with Neodymium magnets so I machined a slot in the corner pieces underside to house the magnets, to be fitted at a later date.

Next job is to fit the roof skins which again will be pinned using the 0.7mm brass pins. The roof skins are now epoxied in place so I need to mark out the position of the secondary panels. Looking at the pieces and the instructions the spacer frames seem to be the same size but I was sure I’d read somewhere that these overhung by 2-3mm, reading Robs blog conformed this to be the case. So some trimming required before fitting and marking out the appropriate position then being glued into position.
The mid cabin was assembled in exactly the same way

I propose to make the rear deck and the deck which carries the tow hook all as a complete piece that lifts out in one. Although its going to be in one piece the full assembly still has to be made as separate components so first job is to cut the individual panels again using the card inserts to make sure the end assembly has clearance. The tow hook deck is the first piece to be dealt with and epoxied as a sub assembly. Having completed the wooden frame I then took a break and did some more planking, first a mahogany boarder and then glue a black card calk around its inside edge, next cut and sand each plank to fit in the space left, these could then be glued in place with a black card calk between each plank. After a period of drying I sanded the whole surface level. Next I put the nail holes in again using the jig I made to ensure uniform spacing and then gave a coat of sanding sealer. When the rest of the subassemblies are complete they will all be lacquered together before final assembly.

I first cut the base material to size allowing a card thickness all round for final clearances. The lower deck has a number of features in it that need to be measured. I took dimensions from the plans and marked out the base. Again following the upper deck which has a mahogany boarder I cut and planed a further amount of 6mm x 1.5 strips of material. I started by outlining the mahogany boarders, Some years ago I made a mitring device for picture framing which has come in very handy for doing the corners. Having all the pieces cut they are then glued and temporally pinned in position until set. The next job is to prepare all the edges with black card and then measuring each plank across the width starting from the centre line. I must take into account how the planks sit against main access hatch and the battery hatch opening however, all seems to look good but until each plank is positioned and glued with its caulk divider it’s difficult to tell. When preparing each plank I first cut each piece oversize with wire cutters then using the disc sander I trim square one end, then place in position and mark for final length and finish again on the disc sander giving each plank a nice push fit
Because lime planking varies in colour across a batch I numbered each plank across the deck varying the pattern of colours as I cut each to length. Next I cut a number of card pieces to length and start to glue (using Aliphatic glue), plank, followed by card filler across the half width, then repeat the other side.
Finally the battery hatch and main access hatch are treated in the same manner.
Next comes the finishing , I use a very fine grade on my belt sander (I attach a block on the underside of the main access deck to control the sanding process) to remove the majority of excess irregularities followed by an orbital sander for a fine finish. if there is any staining by the black card residue I simply remove it with a pencil rubber. Next I put the nail holes in again using the jig I made to ensure uniform spacing and then gave a coat of sanding sealer. Final finishing will be done as a complete assembly. Preparation of the side panels is the next process before final assembly

Now I am in the swing of planking I may as well do all the remaining decks that need planking. Therefore, very much the same procedure as before with a mahogany border, followed by caulking the inside edges of the mahogany border, then cutting the planks roughly to length, and then finally trimming on the disc sander for an exact fit. When all he planks have been dry fitted, they can are removed and glued with aliphatic glue. A couple of days to completely dry then it’s on with the sanding before finishing with sanding sealer I marked all the nail holes using the marking tool I made. This is all on this deck until final finishing which will be done with all the other decks.

Boat lifting eyes
As has been said by others the boat lifting eyes are a small detail but an important one, somehow when detailing gets in your head its difficult not to seek it out. Anyway, there are six eyes three on each side, which I presume, are for lifting the boat out of the water, unfortunately there isn’t any detail on size so it’s down to “builders eye”. I made the six in a batch, that’s to say I first made six identical pieces 10.5mm x 20.5mm x 2mm thick and drilled the hole in each then the six pieces fastened together with an M4 screw and then machined together to ensure uniformity and ease of production. I then skimmed them to final size 10 x 20 followed by milling the concave and convex radii on the top. I intend to sink the eye into the deck and secure using a brass pin sideways into the gunwhale stringers and epoxied into position. To ease fitting I made a small jig, which will allow a 2mm slot to be cut in the exact position on the deck along with a drilled hole at 90 degrees. Two small grub screws fasten the jig to the gunwale stringers while the slot and holes are machined. After all the slots had been prepared I then made all the foot rails that run along the edge of the deck from bow to stern, the first set I used the obeche supplied in the kit, however as they are in a place that could get knocked I decided to rework then in walnut. Finally I pre drilled all the foot rails ready for temporary pinning. Having all the components ready it is time to assemble with epoxy resin, using sparingly and making sure not to get any on the visible part of the brass lifting eyes and using pins to hold in position while curing.
PS sorry about some of the picture quality but I didn't check them until after assembly

The white metal fittings supplied with the kit are somewhat lacking in detail and some are overweight to say the least. I decided to produce some life rings to my specification I had tried to find suitable replacements on the web without success. So how to produce the ring part.
I first tried with plywood but the finish achievable was not acceptable (can be seen in the pictures) so I then decided to use Bamboo (Ikea phone stand) for those who have followed from the start the same material as the grating on the foam tanks. First I cut some rough circles out of 10mm bamboo sheet and drilled a 10mm hole so it can be mounted on a 10mm screw mandrel. This allows the piece to machined on one side and then reversed and machined on the other side. The tool I used was ground with a 22 mm radius to produce the shape on one side of the ring and then when reversed and machined again the tool actually “parts off” the ring on the inner diameter leaving the ring free on the now remaining peg, the finish on the bamboo was good enough without any further sanding. The next step was to put a slot in the OD at 90degree intervals to hold the “rope” in position while the rope is bound in four places. The easiest way was to make a jig to hold the ring and to keep the rope in place while it’s glued into ring, it can then be removed and bound in four places each turn being super glued to keep it in place. Next job is to give a coat of sanding sealer that stiffens the rope and seals the wood. The rings are theoretically held to the cabin roof with clamp type brackets so again to ensure consistency I machined a piece with a suitable profile. I then cut radial slices to create individual brackets. The rings will actually be fastened to the cabin roof with 2 x 8BA bolts this is to enable them to be removed for painting of both the ring and the roof. At a later painting stage, I will be giving them two coats of grey primer and three coats of white, then hand painting the rope loops with red paint. The finished rings are much lighter and hopefully look more realistic.

Rear cabin hatches
I have decided to make these two roof hatches detachable (not working) purely to ease the painting and rubbing down process. The hatches on the rear cabin are supplied in pieces to be glued together, so to make them detachable I drilled a hole through the base of each and glued an 8BA screw in place, these can then be secured after final painting to the roof. The hatch also has a dummy-hinged lid and small white metal hinges are supplied, however they do need some attention, such as drilling all the holes and trimming the edges. Here we go again, time for a jig! Repartition can be achieved with the simplest of jigs; all I used was coffee stirrers pinned to a block of wood and one as a locking device. The jig was then placed under the milling machine and the first hole centred, drilled and then the next hinge is placed in the jig and drilled and so on, move to the next hole until all holes are drilled. Before fitting the hinges there needs to be a separation line for the lid and hinge plate so a scored line about halfway through the ply. The hinges are fitted with epoxy and brass pins through all the fixing holes.

Mid cabin hatch
This is a single hatch, again a square of ply is supplied, but this is improved by adding sides, which can locate on runners, again the runners are not supplied. This hatch is also attached with a single screw epoxied into the top and a nut, after final painting.

Forward cabin hatch
Again, a single hatch and dealt with in the same way as the mid hatch.

A working search light seems to be expected on this craft so here goes. Based on Robs build I purchased the lens and the LED from Maplin’s which seemed to fit the bill. The only piece that will be used is the main body that is supplied as a white metal fitting, the rest will be replaced by a brass construction, as the rest of the parts are not substantial enough to support a working unit. First, I need some 3/16 half round brass bar, the easiest way is to machine my own cutting just less than half the diameter away. The half-round bar was annealed before bending round a suitable mandrel to a half circle. I then soldered an 8BA nut on each leg to act as the swivel bearing. Next, I machined the body’s internal bore to suit the lens body and skimmed the outer rim and face, finally bore out a small recess that locates the lens in place. The two pivot holes need to be drilled and tapped 8BA, and then a drilled hole in the rear wall for the wires to exit. As the light is to be both working and rotating the base has is to be made with a centre spindle that connects to a micro servo under the roof. The connecting devise was a bit of a headache trying to make it fit in a relatively small space; I used the supplied servo arm with four legs (shortened) and then machined a mating part with pins that located in the arm that is attached to the body above deck. The LED was modified to fit in the white metal body as it has a heat sink which was too big; as others have found cutting it down didn’t affect the heat dissipation when fixed in the white metal body, this was fixed using a small amount of Milliput. Having already machined the outer flange on the body I turned up a brass-flanged ring to push fit on the body this has to have the TRI form guard added. I made this from a central pinion with three holes drilled to accept the bent brass nails; these were soft soldered in position. The TRI form was then located on top of the brass flange and again soft soldered in position At this point all the components will have to be dismantled for final finishing before being painting.

This is a small item but very visible on the wheelhouse and since the standard for this item has been set I have to follow suit. So first of all get some 3mm blue LEDs ordered and then it’s on with preparing the white metal body. I used by hand as suggested a series of drills increasing in diameter until 3.1 dia was reached but only 2/3 down the length from the front the smaller hole (1.5mm) was bored right through for the wires to exit. Arrival of the LEDs, first check the LED using my power supply, just over 3 volts seems to illuminate to the correct level. Next was to remove the shoulder on its plastic casing so the whole body does not exceed 3mm over its length and lightly abrade the outside to give a diffused light. Next cut the LED legs to 2mm from the plastic casing noting which is positive, next prepare the wires. I used Futaba servo wire cable 22awg which is very flexible and with the white signal wire stripped off leaving a red and black wire. These were tinned and cropped to 2mm and then quickly soldered to the appropriate terminal. Next check the LED still works! first hurdle over, I now needed to check the that when the LED goes into the body it doesn’t short out so checking the diameter over the widest part which is over the soldered terminals this was 0.1 below 3mm. I decided that shrink sleeve was too thick so I mixed some epoxy resin and coated all around the terminals, this proved to be satisfactory in both non-conductivity and dimensionally. Now the final test, using some aliphatic wood glue I slid the LED into the body whilst it was illuminated as it was a tight push fit, bingo it’s still lit – leave to set. I used aliphatic glue, as it would be easier to remove should I ever have to change the LED. The body still needs painting white but this will be done with all the other fittings at a later stage.