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flat out flatting out

Inbetween all the outboard engines coming in for service , breakdown call outs and engine repairs, the phones not stopped ringing and my ears hurt.

Im not sure if its from answering the phone non stop or the noise of the sander going for

8 hrs a day. We're making good progress on the rebuild of the "Jays Helping Hand" Charity Boat.

Under all the layers of Paint we found a boat hull.

Its been a tough one this, as being a 1975 boat its had 45+ years of dings , dents , paint and filler and not all of it good at that.

So we're half way down one side of the hull now and its starting to look good ,After much filling and sanding the hull is now fair up to this point.

After a meeting with the owners, A final colour choice of light grey topsides and a slightly darker grey hull was decided on, then fitting four berths (two in the cabin and two in the cockpit) along with a toilet (heads) , galley and some form of heating. We are also going to raise the wheelhouse roof by six inches.

As the windows are not up to scratch we are going to replace these with somthing similar to the little blue and white fishing boat we did the windows on not long ago .This is one of those projects I can see myself really enjoying.

This boat is going to need a lot of fiberglass work, there are plenty of holes left over from skin fittings and old vent holes that all need to be correctly repaired.

so starting with a fairly large hole we start to taper the edges till the edge of the hole is about as thin as a peice of paper.

once this is done we place masking tape over the back of the hole we used 2 inch tape here.

then taking your glass mat In this case 300gsm we cut six circles the first one just a tiny bit bigger than the hole in the hull and then making the next one slightly bigger until you end up with six circles each one bigger than the one before .

Then we brush a very thin coat of resin on to the sanded surface of the hull.

starting with the smallest circle we brush just enough resin on to both sides of the glass mat to wet the cloth it shouldnt drip off but it must be wet all over and both sides.

then with a stiff brush we stipple it on to the hull covering the edges of the hole and the masking tape then we repeat this process with each circle of mat until we use the last one (the biggest).

Wait for the resin to start to go off. When the left over resin in your pot goes rubbery, remove the masking tape from the inside of the hole and wait for the resin to cure fully (about an hour).

Now all we have to do is dish the inside like we did on the outside and repeat the process on the inside of the hull , Then sand the repair to remove any wax from the resin and finish with a skim of filler( resin mixed with sillica powder).

This is going to be a big repair but thats for another day , Only another thirty foot to go.

Now where's that sander?.

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