very impressive build. imagine how easy that would have been for wellcraft to do 30 or 40 years ago.

thanks for the photos and detailed descriptions

love watching this stuff.:clap:

And here's the bilge drain sleeve all cleaned up on the inside.

https://drive.google.com/uc?export=d...gmOIpcOahZFZTo

Then my friendly UPS driver backed all the way up into my driveway to help me B.O.A.T.:

https://drive.google.com/uc?export=d...risH0ZssX05oTE

13.3 gallons of epoxy, more Cabosil, microbeads and gel colorant, and 40 yds of 17oz biax. I think that'll be the biggest single ticket order until I get to replacing the leaning post, adding a t-top and whatever I decide to to with the outboard.

Made up a mount to hold one of my high power laser pointers for laying out the stringers, then after the underwhelming storms powered through I power washed the whole thing. Could've gone a little lower on the drain hole but it's still much better than it was originally. Right now I'm just glad to have all the current grinding dust washed out for the next step. Cheers!:beer:

I'm amazed at the progress you've made. Can't wait to see splashdown. I tip my hat to you sir!

Thank you! I'm really looking forward to the forecast break in the heat that's supposed to come tomorrow night, That will make throwing the bunny suit on to continue grinding a lot more bearable! As I marked out rough lines on the hull for stringers tonight I decided I didn't grind out far enough for the tabbing to come, and circled a few spots that I want to add a little glass to for reinforcing. Time to order up more grinding discs!

Agreed! Especially with plenty of supplies at the ready, very little extra material or labor would've been involved! But I guess then they wouldn't be able to sell you another one quite as soon...

Thank you! I'm glad my contributions are being enjoyed!

Yesterday evening after work I took advantage of the drop in temp to climb in the suit and cut a bit. Got the sole partially stripped. As expected all of the plywood was rotten and delaminating.

https://drive.google.com/uc?export=d...8SPcLqUULlAout

https://drive.google.com/uc?export=d...H55It0iiGiiRWs

https://drive.google.com/uc?export=d...WjWdMWcpPfhkIV

And then today I stripped a little more before deciding the wind was too high to cut and grind without perturbing the neighbors. So once I power washed the cap down I pulled out the stringer stock and started on the stringers. I started with my laser pointer setup to get my heights:

https://drive.google.com/uc?export=d..._om84H4L7E0RKk

Look close and you can make out the green dot back on the transom:

https://drive.google.com/uc?export=d...72E12hYw4yZpzu

I set the height by a couple of strings through screw holes in the hull transposed from their matching holes in the cap where I measured precisely to the underside of the sole, and compared it with my records of dimensions before cutting the stringers out:

https://drive.google.com/uc?export=d...H4TJutGm2dqza8

https://drive.google.com/uc?export=d...k5dF6bxr8L9QTW

Took new measurements from the hull to line and transposed those new dimensions onto the stringer stock:

https://drive.google.com/uc?export=d...fFauMjWtVr1Dxl

And traced the tail and utility cutout profiles from the original stringer shells:

https://drive.google.com/uc?export=d...M3zvet0wzeId3-

Cut carefully and set it in place for a test fit:

https://drive.google.com/uc?export=d...BNUYAVEYMrzB5C

https://drive.google.com/uc?export=d...LPpbNdfrTwRG7i

Measured to make sure I had the right offset from the reference laser line, made a few adjustments and then repeated for the starboard side. Voila - two accurate fit stringers:

https://drive.google.com/uc?export=d...1hCFW9Ewd0k0tQ

https://drive.google.com/uc?export=d...RlKIx0UK280qi3

https://drive.google.com/uc?export=d...ycO7dl18zJiq_B

Then carried each one downstairs to the router table and put a 1/4" radius along the top edge to ease wrapping the 17oz biax around the profile:

https://drive.google.com/uc?export=d...e1_9Jg5nw0x_kb

Tomorrow I hope the weather (specifically the wind) cooperates to let me grind and wash down the hull so that I can proceed to bedding these two in place.

Hoping this is a VERY productive Labor Day Weekend here. Here's what I was up to this week.

Took the stringers back down into the shop and worked on glassing the curved features on them. Glad I elected to do it in the comfort of the shop instead of in place. I was able to experiment and get a feel for how to conform to the curves. First one wasn't the prettiest and required lots of additional sanding but it is covered. Here's the second one where I started to get the hang of the right approach. Still room for improvement:

https://drive.google.com/uc?export=d...3r9ShufsbmIRYs

Yes - the shop needs for it to rain one day (or 7...) so I can straighten things up - it's even more disorganized than what you can see in these photos.

https://drive.google.com/uc?export=d...2SHEzgrrFt2SNS

https://drive.google.com/uc?export=d...5HR_tEWwsY6qCh

https://drive.google.com/uc?export=d...eYkpASuF_9aaM4

https://drive.google.com/uc?export=d...Nwa5N-Uz_vAAuC

Then spent a night sanding them clean. With that out of the way I laid them in the hull, aligned the top edges and tacked them in place with peanut butter.

Came back the next night, lightly sanded the tacks and filleted them in 100%:

https://drive.google.com/uc?export=d...SnHnWWQB4883fh

https://drive.google.com/uc?export=d...pAMkUZ0IwdxGuT

https://drive.google.com/uc?export=d...jwPlTJuozOfx_g

https://drive.google.com/uc?export=d...emq5UGVFgi461V

The boards clamped in place aren't the bulkheads, just spacers to align the tops and spacing and keep everything parallel:

https://drive.google.com/uc?export=d...CvSTthJDXt6b3a

https://drive.google.com/uc?export=d...BVUtVipbm-AKif

https://drive.google.com/uc?export=d...oCrDfE2ibeV8pt

That wrapped up the work week. This morning I took a 90 mile road trip and snagged a new (to me) tandem axle trailer:

https://drive.google.com/uc?export=d...NkTDASXyfWyNaw

Might have to make a small adjustment to the bow roller and winch mount but other than that it is sound and pulled like a feather on the drive home. Brakes on both axles and the bunks and carpet are in great shape for a salvage yard find. Just need to get 2 new tires.

Once I got back to Louisville I dove into sanding the fillets in preparation for glassing. I've been watching Boat Works Today videos on youtube and Andy recommended a handheld belt sander. He uses a Makita that retails for around $250. I couldn't (at the time) justify that pricetag so I snagged a smaller Wen off Amazon for about $35. I gotta say - this is an EXTREMELY versatile tool. Made easy work of sanding the fillets and tight areas between the stringers and strakes a relative breeze. If you're thinking about tackling a project like this I can't recommend one of these highly enough. The only draw back to this is the belt being so narrow makes it wear pretty quick. The dust collection isn't perfect but it's leaps and bounds better than using the grinder, and removes material almost as effectively. I just might pull the trigger on that Makita in the near future to get a little wider belt and larger radius on the head:

https://drive.google.com/uc?export=d...QnKjrVMZQnzj8M

They're all sanded, vacuumed and washed down now:

https://drive.google.com/uc?export=d...G2g63xQ6lOg7D5

https://drive.google.com/uc?export=d...ufaf3q6zyjfz1L

https://drive.google.com/uc?export=d...kglLh894wj8n3j

https://drive.google.com/uc?export=d...kEpAzUUE6YzDS7

Tomorrow morning I'll start cutting my sections of biax to prep for glassing. My goal is to get the starboard side glassed in tomorrow. If things go smoothly the port too, but I'm not holding my breath! I've slightly modified my layup plans. I had grand plans to do the whole length in a single piece but I think now that the time is nigh that plan was a wee bit overzealous for my experience level. So instead I'm doing 50x50 sections, overlapping the joints and staggering the layers.

Hope everyone else is enjoying their long weekend, hopefully out on the water, or like me - watching the long awaited triumphant return of college football - especially the University of Michigan! GO BLUE! HAIL HAIL!

Suffice to say I am exhausted. Took a long time and a nudge from my brother in Ohio to decide to have a margarita and some dinner instead of just going to bed. 12 1/2 hours, 6 gallons of epoxy and 22 yards of glass later the stringers are laminated.

I made up a rod holder on the side of my gantry to hold the rolls of glass, and set up one of the sheets of plywood that's waiting to be used for the bulkheads as a cut table early this morning.

https://drive.google.com/uc?export=d...gBpICo_M5LXt7V

Felt like home ec class 30+ years ago all over again.

https://drive.google.com/uc?export=d...oENPFDch1p9xkQ

I started off trying to use rollers and smoked a couple batches of epoxy and trashed a roller frame so was in and out of the hull more than anticipated. The result...there might be a bit of grass laminated in the bilge... Threw down a layer of plastic which helped that, but unfortunately it liked to slide around on the excess epoxy draining out and to my shoes which have a nice healthy coat. A word to the wise - don't wear slip on shoes when epoxying - they might be convenient but when they get sticky they tend to slip off just as easily as they slip on!

https://drive.google.com/uc?export=d...-SeIK7hGeviwgn

But I got it done, including a layer of 1708 down the keel/bilge.

https://drive.google.com/uc?export=d...7sMmPu2GviWuzg

Left a little tag for whoever pulls this hull apart next:

https://drive.google.com/uc?export=d...NZzCNWdrcLZMBu

That's a lot of epoxy...and based on the estimation from West Systems' page I only exceeded the estimate by a quarter gallon - and based on the smoked batches I tossed - I'd say it was spot on.

https://drive.google.com/uc?export=d...OX674Tk0Uklq5U

I know the layup isn't perfect - there are bubbles and I'm going to have to either drill and pump in a fill or grind and reglass a few spots on the fillets. I think the heat was too much today for this epoxy formulation - they laid down flat but then it really seemed like once they started to gel the whole lamination shrank. If I were to ever do this again (highly unlikely! LOL) I would laminate up each side of the stringer and then cap the top instead of trying to do a full wrap from tab to tab. Hindsight is 20/20. Should've followed the process so many others have used.

Tomorrow will be a well deserved day of relaxation. All I plan to do is pull the 2 worn tires off the new trailer and maneuver the trailer into the back yard so I can unhook it from the truck and then cut the grass. Happy Labor Day y'all!

Greg