Saturday, October 27, 2012

Outboard Enclosure-Part 2

Continuing with the back of the Outboard Enclosure.



Here is the back in its form.  Again using 2 layers of mat and 2 layers of fabric alternating between the two.















Added wood for structural support.  The 3 square notches will accept 1" square tubing, which will in turn support the fuel tank.














Squeezed into place.  Three lag screws were placed from inside the hull out into the wood structure.  Also tabbed the back of the enclosure to the two sides with one layer of mat and one layer of fabric on the inside.












The motors clear the back by less than half an inch when tilted upward! Yikes.

I will fill in the gap between the back of the enclosure and the hull beam with a swim step.











From the opposite side.
















Close up showing wood fiberglassed in.  The fiberglass was "x"ed out at the 1" squares.  Actually the holes are about 1 1/4" square so that when the fiberglass is folded inward, it will make for a tight fit around the 1" square aluminum tube.








A Side Project

A couple of shots of filling in the holes left by removing the outboard controls.  They will be relocated at the new helm station.  Unfortunately, I was unable to neatly remove them due to seized bolts etc, so the holes left are bigger than necessary.

 
For the backing, I used a piece of melamine board wrapped with a piece of 7 oz fabric and screwed it in from behind.  After I remove the board, I will add resin to fabric overlapping the holes to tab it in place.


The maroon color is from my failed attempt at a fairing mix.  Added enough micro balloons to achieve a mayonnaise consistency, but after 2 days, it was still soft.  I think I put it on too thick!  Decided to add another layer of fabric.








Now on to the Enclosure Lids....Part 3.... Stay tuned!

Saturday, October 13, 2012

Outboard Enclosure

OK, so henceforth, this project shall be referred to as the "Outboard Enclosure" for lack of a better term.

I decided to start with building a mold to create the sides of the Enclosure.  This will yield a smoother surface from the beginning.  I am using melamine, since it is impervious and the resin will not stick to it.





















This is after 2 layers of cloth and 2 layers of fabric, alternating between the two.


















Here is the starboard side, right out of the mold.  The melamine really worked.  Didn't need to use any wax or such.





I decided to add some wood for structural support, since the sides will be subject to people standing or sitting on the outboard enclosure.

This is the port side.  I forgot to take a picture of the starboard side before mounting it.





Added a layer of fabric and resin for good measure.


You can just make out the lip I created during the form process that will support the lid.

I removed enough teak wood trim to allow for the overlap on the hull.  I used 3 lag screws coming from inside the hull and screwing up into the wood.









Port Side of Enclosure






View from starboard top.  I used 2 lag screws which again were screwed from inside the aft berth area out into the structural wood.
















View from above.




View from Port Top.  The sides will also be tabbed into the hull and stern to provide extra rigidity.











Back of Enclosure is next

Here it is formed up