The slippery slope continues...

The slide into more painting projects continued today as we expanded the locker painting to include the portside salon bench and lockers.  No doubt they need the attention...

Upon attempting to sand the lids to the lockers we discovered the plywood was cracked, so two new lids coming right up.

 We did progress from the prep to the priming stage with Anne doing her time in the lockers.

Greg from Paradise Welding spent the morning completing the polishing work on the gallows.  He does an amazing job and the welds are not visible.

Can you all find Anne hidden in the image above?

Greg also dropped off the tubing arch for the bimini project.  We have decided to go with building a hard bimini ourselves and are awaiting the arrival of some fittings for constructing the frame.  Once we have the fittings in-hand the bimini construction should move quickly.  

Hanging the gallows

We hung the gallows today!

The act of hanging the gallows, drilling the final four bolt holes and tightening down the bolts, was not a challenging task.  The satisfaction of installing the finished product and nearing the completion of a project started two months ago is a feeling to be relished.

Note in the image above the stern rails originally ended at stanchion (vertical post) that slopes aft.  We added the forward section as bracing for the gallows.  This has the added benefit of providing more security in the cockpit and a great backrest when sitting atop the cockpit combing. There are still lingering aspects of project - polish the new welds and possibly purchase/create some leather covers for the cradle sections of the gallows.

In the images above and below the dodger is missing since we are continuing to refinish the wood on deck. 

To me the gallows looks much larger with the dodger absent.  We did complete all the brightwork this afternoon and plan to reinstall the dodger tomorrow.  I'll post a set of pre  & post gallows images once the dodger returns to the picture.

nearing the finish line.

Before...

 and after...

The difference is four coats of Bristol Finish. Since the lazurette hatch has previously been finished four coats is enough.  For the boom gallows and the  generator box, I will continue on until there are 7 coats of Bristol finish per side.  It feels good to be nearing the finish line on these projects.

80 grit, 120 grit, 220 grit... gett'n gritty with it.

60 minutes with a circular and a jig saw was the prelude to a couple of hours of sanding on the gallows going from 80 grit, to 120 grit, to 220 grit per the instructions on the Bristol Finish.  The image below is from my preferred sanding work area the back porch of the lodge (and, yes we are in the process of repairing the riding mower or have we installed a rocket and the Husky is prepped for launch?)

I have previously used Bristol Finish on C'est la Vies bright work and am pleased with the longevity of the finish and the ability to apply multiple coats, wet on wet.  By applying the two part finish wet on wet four coats can be applied in a single day without sanding between coats.

Below is an image of the completed gallows cross piece.

 With the gallows ready for finishing, I turned my attention to the joinery work necessary to complete the air tight box for storing the generator below decks.  Complete the fabrication of the wooded trim and lid will allow me to apply Bristol Finish to the wood on both projects at the same time.

 In the foreground of the image above  the lid is dry clamped together to test the fit.  In the background is the box.  I have applied blue painters tape to the lower section in preparation for  attaching the base trim with epoxy.  I don't want to nail or screw the trim onto my airtight box...

testing, 1-2-3, testing

I started off the day by shopping on-line for some ear plugs to use while snorkeling. Snorkeling daily during the summer of 2008 proved problematic for my left ear which became impossible to clear by popping and constantly felt congested. Google lead me to some articles on the DAN site which lead me to Doc's Proplugs.  I will report out on the plugs effectiveness later.

Once the bugs had retreated from the rising sun, I applied a 3rd and final top coat of paint to the generator box.  The next step is to began manufacturing the lid and trim from 1/2" mahogany plywood.

Mid morning found Anne and I installing the wooden crosspiece for the new gallows. The crosspiece is in the rough cut stage and before moving forward on sanding and finishing I wished to test the shape and dimensions while sailing. 

The image above was taken motoring out Indian Key Pass.  The boom is resting solidly on the gallows.  Also of note is our new tiller extension.  Anne has suggested installing a tiller extension for years and after one short day sail with the Spinlock extension and I am wondering why we waited so long.

Due to light winds on our stern we motored out to the Gulf.  The trip out to the Gulf also afforded us the opportunity to test the engine cooling system.  The previous afternoon with the Kubuta seems to have resolved our cooling troubles.

Approximately 1NM offshore of Indian Key and in 11 feet of water, yes it is the west coast of FL, we shut off the motor an let C'est la Vie drift while we scrubbed the hull and took in a lunch.  By early afternoon a fresh east wind was building.  Perfect time to test the gallows by tacking back into shore.

The gallows worked well in all points of sail, but the clearance between the boom and the gallows while sailing close hauled was a scant 1.5 inches.  Manually forcing the aft end of the boom outboard or downward  would bring it into contact with the wooden crosspiece.  I fear that in heavy seas the boom may begin to strike the gallows.  Fortunately we can trim 1 inch off the top of the crosspiece without loosing any structural integrity.  The loss of the material will result in more shallow notches for the boom's resting positions, but I'm willing to give up some depth on the notches to gain an additional inch of clearance between the gallows and the boom.

back to the woodshop...

progress on many fronts (a.k.a our first day back to FL)

With many miles now in the mirror and our rental car returned to the Hertz stable, we spent our first full day back in FL making progress on many fronts.

 The day started with a third coat of primer on the generator box and concluded with the application of the first coat of topcoat.  I am using Interlux Brightside Matterhorn White for the box.  C'est la Vie's hull is Matterhorn White by Awlgrip.  Using the Brighside for this project provides the opportunity to test the paint's application & qualities as the clock ticks toward the day when we need to repaint C'est la Vie's topsides.

While the morning coat of primer dried Anne and I drove to Marco, yes more driving, to meet with Bronwen, a local sailmaker.  We picked up or jib on which she had replaced the clew - see image below...

 We were pleased with the quality of the work so we dropped off our genny so that she can replace the aging clew on that sail as well.  While at the sail loft, we discussed options for creating a bimini now that the boom gallows project is nearing completion.  One of the purposes for adding the boom gallows was to provide a stable structure to which we can attach a bimini (A bimini is simply a structure, ususally made from canvas, that provides sun and rain protection for people in the boats cockpit area.)

Returning to Sunset Island in the afternoon, Anne went to work mowing the yard while I began shaping the wooded cross piece for the boom gallows.  I completed the rough cutting and began sanding prior to the onset of bug hour - see image below...

The next step will be to mount the gallows on C'est la Vie to ensure the fit and aesthetics of this piece.  We also need to locate the position for the port and starboard notches for the boom.

bedding & backing

Anne and I spent the day bedding - filling any voids in the assembly and holes in the deck that may allow water penetration - and then installing backing plates - 1/4" thick metal plates that are mounted below decks to insure forces placed on gallows are distributed over a large area of the hull.

First we started below decks and used cardboard replicas of the backing plates to locate where on the plates we would need to drill holes for the machine screws.  Once we confirmed the hole patterns in the backing plates were correct, we loosened the nuts on the screws currently holding gallow's bases to the deck of the boat. With nuts backed out to the end of the treads we went topsides and used the main and jib halyards to lift the gallows bases off the deck.  This gave us approximately 3/4" of a gap between the deck of the boat and wooden base of the gallows - see image below. 

After taping off the surrounding area, Anne brushed unthickened epoxy into the gap - see image below.

We then mixed up a batch of thickened epoxy and used a syringe to inject the thickened epoxy under the base. Easing the halyards lowered the assembled gallows back down onto the deck and as expected the thicken epoxy oozed out around the bases.  This will create a watertight joint with the deck - see finished product in image below.

With the base sealed to the deck we then turned our attention back to the plates below deck.  We mixed up batches of thickened epoxy and spread this atop the backing plates.  As we tightened down the plates using the machine screws, pulling the plates in contact with the underside of the deck, the epoxy filled any voids between the backing plate and the underside of the deck.  Once cured the epoxy will create a uniform surface between the plates and the deck.  The image below is of the port backing plate installed.

a leap forward

Yesterday, May 7th, we moved the boat over to a friend's dock on the mainland and Greg from Paradise welding traveled down to Everglades City to install the metal post and braces for C'est la Vie's new gallows.

Greg is pictured in the image above welding on the extensions to our existing stern railings.  These extensions provide more security in the cockpit and bracing for the gallows.

Once the welds were completed then the polishing began.

We still have numerous facets of this projects to complete - polish the welds, finish the cross brace, install backing plates, bed the thru deck bolts, but it does feel like we made a leap forward yesterday.

Paint, primer, and progress

Progress, progress and the project lists continues to shrink. 
Anne has repainted the floor and engine room wall in the quarter berth (a.k.a. the guest suite).

A

And I continue to prime the gallows bases...

above is pictured coat #3 of primer. I also continue to fair out the generator box with filler to provide a smooth finish and neat corners.

 Before....

After...

We are awaiting Greg from Paradise Welding to make the trip down to Everglades City for the installation of the stainless steel posts for the boom gallows.  Tentatively he is scheduled to work on site either later today, Wednesday, or Friday.  Our plan is to ferry C'est la Vie over to our mainland neighbor's dock for the installation.  We will keep you all updated.

time to focus some attention below decks

Due to a plumbing emergency on Sunset Island my time for boat projects was reduced yesterday.  I resolved the plumbing leak late in the afternoon and decided the countdown to bug hour here on the island would not provide me with the window necessary to continue fairing the gallows bases.  Thus I choose to focus my energies below decks.
 
The gallows will require a sizable backing plate below decks.  The backing plate will need to sit flush against the underside of the deck.  This required me to cut away a section of the existing headliner below each of the bases. Fortunately these cutouts are in less visible locations - the starboard quaterberth and a port side storage area.  Based on my experience cutting away the decking during a project to re-core some of our decks, I chose to use a 4" grinder with the cut off wheel to remove the liner.  After marking off the section to be removed, I sealed off my work space using masking tape and plastic sheeting.   The image is of the starboard side quaterberth.  My goal is to reduce the amount of dust circulating below decks - cutting fiberglass is a dusty job. 

Once the area was cut away I used the orbital sander, lower center of image, to sand down the exposed surfaces in preparation for filling irregularities and voids with epoxy.  Since the area was tapped off and I had a sander in-hand.  I could not resist expanding my project to include sanding and repainting the floor of the quaterberth and the engine room wall.  No time like the present... right?

Along with concerns over dust in the boat, I certainly do not want to inhale any of the byproducts so appropriate safety equipment is necessary.  The images above are post cutting and sanding.

Fairing

On both the generator box and the boom gallows bases, I continue to fair out (or should I say in?) the projects.  This means I am using thickened epoxy to smooth out rough edges and make things look aesthetically pleasing.

Well on the generator box is a bit more than just aesthetics.  I did smooth out the upper edge of the box.  Since the box must be air tight, the quality of this edge is very important as it will press against the gasket material to form the air tight seal.  I used epoxy thickened with 407 filler to create the edge.  Once the epoxy had begun the kick I used denatured alcohol, my fingers, and a razor knife to sculpt the edge.  A bit of sanding a few hours later and val la...

Meanwhile after a similar process on the gallows bases...

The next step on both of these projects will be to use 3M filler for the final fairing.

back to the bases

After spending the afternoon yesterday in Ft Lauderdale waiting on Nance and Underwood rigging shop to modify the lifelines and this morning focused on NOCBS' responsibilities, I made some progress on the bases for the new boom gallows this afternoon.

The image above is of the bases after removing the modeling clay mold and some sanding.  The cream colored base consists hardened epoxy thickened with a high density/structural thickener. This will provide a strong platform on which the base of the gallows will rest.

I then taped off the surrounding area in preparation for adding some epoxy thickened with a less dense/fairing thickener.  This will allow me to sand down the fillets and base to provide a nice cosmetic finish.

With the epoxy applied it is now a waiting game until I can begin sanding.  Since I used a slow hardener and we are nearing bug hour here in the Everglades, the sanding will happen tomorrow morning.

two epoxy project does slow going make....

Each project that involves fiberglass and epoxy work in which I engage definitely increases my skills with the medium, but I have yet to gain much ground in the efficiently arena.  I continue to make slow progress on both the generator box and the gallows bases.

Here is the box..   Since the last update I have added mat to the sides and outside edges.  I have also begun to fillet in the inside corners. The brown areas are fared in using west 407 density filler.  This will enable my to give the finished box a smooth surface.

The next steps are to cover the top edge with mat and finish the interior corner fillets.  Once these tasks are complete then I will begin work on the lid.

And here on the gallows bases... After cleaning, sanding, and filling the bolt holes left from the old stanchion bases,  I created a mold for the new bases out of modeling clay.  The template for the mold was a bowl from the kitchen (don't worry Anne approved) and a straight edge.  Once the molds were complete I then poured in thickened epoxy.  I did two separate pours to avoid excess heat generation caused by the exothermic reaction of the curing epoxy.  Heavy layups of thick epoxy can generate enough heat to damage the deck and compromise the integrity of the curing epoxy.  Two pours also provided me with greater control over the accuracy of the coverage and thickness of the layup.  The next step on this project will be to remove the mold and fair in the new bases.

good progress on both projects

Making progress on both the boom gallows and the generator box.  This morning, the inner, cardboard mold slid easily out of the generator box.  I must admit I was a bit worried that the epoxy the dripped through the joints would make this a nightmare, but my fears were unfounded.

Anne and I also removed the stanchions and bases at the site of the boom gallows on C'est la Vie.  With Anne's assistance this also went much more smoothly than anticipated.

prototype cross piece completed

Above is the prototype gallows cross member.  I used different designs for the right and left sides so that Anne and I will be able to choose our favorite design.  I'm leaning to the right side due to both aesthetics and structural integrity  The finished produce with have three notches across the top for the boom.  I am afraid that removing additional material from the left side will weaken to cross brace.  This prototype is 1/4" thinner than the finished piece, but I still have my doubts about the design on the left side. 

Next steps are to drop this piece off at the metal shop, begin work on the wooden bases, and build up the deck to accept the base of the gallows.

the design process continues

I dropped off the 2" steel tubes and met with the guys at Paradise welding about the design on Friday.  With the metal at the shop, I am now turning my energies towards creating a prototype for the wooden cross piece.

In the image, the left piece of wood will be for my prototype and the  darker wood on the right is the actual piece of sapelle that will become our new gallows.

Still measuring....

Moving on from the wooden cross piece, now we need to create dimensions and a sketch for the metal work. It is more daunting that the wood because the cost of errors will be in both materials and labor.

It is also not the most glamorous or fun portion of owning a boat or even of this project, but it is impossible to escape the need to be diligent and exact in the phase of the project.

Measure twice...cut once

With the steel polished, the next step on the boom gallows project is to rough cut the wooden cross member. The staff at Seafarer Marine in Fl Lauderdale recommended Sappele, a member of the Mahogany family. At their suggestion purchased a 10 foot section of 2"X9". As with all construction projects the mantra with this step is measure twice & cut once. Looks like we will have 3' section of wood left over for another project.

With the steel polished and the wood cut to length, my next step will be to take all the pieces to Paradise Welding in Naples to ensure that we are on the same page with the design process and production calendar.

first we polish the steel

Perhaps the most ambitious of our spring boat projects is the creation/addition of a boom gallows to C'est la Vie. We are creating the gallows to both provide a crutch for the boom while at rest and to provide an attachement point for a cockpit bimini. C'est la Vie's boom end sheeting has made it difficult for us to find an bimini design that we feel is sturdy w/out detracting from the aesthetics of the vessel. Our solution... add a gallows and design a custom bimini.

Thanks to a family friend we were able to obtain the requisite stainless steel tubing and plates for the price of polishing our own steel. The tubes were delivered with a dull finish. So one afternoon with a polishing wheel on the grinder later and the steel is ready for the metal shop.
FYI the lower half of the two tubes on the left are unpolished in the image.

I have also purchased a 3" X 10" X 10' piece of Sapelle for the wooden section of the gallows. Step two will be to begin shaping the wooden cross brace.