Transom glued up!

Ok. Ive been off the radar for a few weeks for several reasons. Namely: Job related problems now solved, my marriage, my inadvertent cutting-off-the-tip-of-my-finger winterizing my garden which led to a giant bandage and stitches, and my work that takes me on the road. Im suposed to be on the road today, but Im not because I have a massive head cold and I think my eyeballs are going to pop out of my head. So no work for me.

About two weeks ago, I glued up the transom. Storer recommends not using screws in the transom, I think this is for aesthetic reasons. I did use screws as opposed to the nails I had been using for the BHs, primarily because I could get a slightly tighter fit. I did not use nails on the transom head-board because I wanted to maintain the visual integrity of that piece, and I was able to secure it in spot with clamps through the tiller-hole. Everything came together really nice and I am pleased with the result. I was careful to wipe away the excess, and I was sure I had gotten everything, but I didnt. I came back and found hardened drips that materialized sometime during the night and they dripped onto the stern-stern of the transom. Using a chisel to cut them off, I ended up mucho-biting into the top of the transom and took a chunk out of the ply. OH WELL. I saved the piece and will epoxy it back in.

Otherwise, I think the transom looks good!

Moving along

A bunch of small items were taken care of today despite my continued head cold and heavy congestion. Sneezing and coughing and snotting all over my boat was a great experience, really.

Anway, All the BHs are beveled, I notched the top frame on BH3 where the middle 90mm was supposed to have never been applied (room for centerboard case), and I cut and traced out the timber for the stem. I also cut the holes into the BH 2 and 3:


Theyre still rough, I havent sanded them smooth or even yet. You may notice I went for the trapezoidal shape on BH2, this was at first done because I was a little nervous doing circles with the jigsaw a la transom. After I did it, I thought, damn, that looks bad. But then I realized that without the curves I can stuff more equipment (picnic basket, wine, beer) in that forward space between BH1 and 2. So I liked that, but then I waffled back to cutting a bigger hole to get curves. At this point my wonderful wife wandered in as I sat perplexed, and she gushed at how imaginative I was for mixing and matching shapes for the holes and how great it looked.

The trapezoid stays, gentlemen.

Up next:

• Shape and finish the dreaded stem
  
• Cut timber and scarf chinelogs
• Apply re-enforcement on transom for rudder
• Cut notches on BHs for chinelogs
  
• Coat all BHs with epoxy (I may do this later because Im getting impatient to see the boat)
  
• Glue up the sides
• Touch up with the plane
• Screw it all together for a dry fit in the garage
• Freak out as I try to find a warmer place than the garage to put it for the winter so I can work on it.
  

Americas Cup Day Four Removal of Doubt

It was no surprise that Kostecki got the hook. Team Oracle has nothing if not a lot of depth on their bench and Ben Ainslie is certainly a qualified tactician. But it was also no surprise that they achieved the same result with the new guy. Oracle is sailing scared. If they get ahead of TNZ they are nervous that theyll get passed. If they get  behind, they have no confidence that they can pass. This sets them up for mistakes, and they have certainly committed more than enough to send the Cup back to NZ.

In race 6, Oracle won the start and the first run. But then they were so concerned about getting rolled that they failed to stick to a winning strategy. They went around the wrong mark at the leeward gate and that pretty much sealed their fate. Out of phase with the tide and their competition, they struggled to get back over to the right side of the track only to have TNZ pummel them all the way to the weather mark. By then it was over.

It was only a matter of time before TNZ would win a start. In race 7 they did that and simply never looked back. I dont know exactly how many practice days team Oracle has had, with or without Ainslie, but its pretty clear that they have not had the same amount as the Kiwis. It looks to me like the Oracle crew is still on the steep part of the learning curve while TNZ is certainly well beyond that stage. Perhaps Oracles crash last October took too much of a toll in terms of sailing days for the crew. Perhaps there is too much internecine friction within the command structure at team Oracle. Whatever it is, this team is not living up to its potential. The betting now is whether Team Oracle can win even one more race before the Cup is shipped to Auckland.

Americas Cup Day 3 Disaster for Oracle

It was a beautiful day on the Bay, with plenty of wind and lots of current at the start of the days racing. These were perfect conditions for the local boys to show the Kiwis about racing on San Francisco Bay. It was TNZs turn to enter the starting box first and they should have had the advantage, but Oracle was able to maneuver into reasonably good position just to weather of TNZ when the starting flag dropped. They accelerated faster than TNZ which was not able to establish an overlap at the first mark. Oracle looked good on that short reach, showing better straight line boatspeed and rounded clear ahead of TNZ. They maintained their lead all the way to the leeward mark. They came in on starboard tack with a comfortable lead and should have simply rounded the mark and hardened up onto a starboard beat and left it to TNZ to tack, and then keep a loose cover on them. Instead, someone in the back of the boat decided to round the mark and tack immediately. Disaster!

Anyone who has ever sailed a catamaran knows they are slow to tack. When you round a leeward mark you want to at least get back up to speed before you throw the helm over. Somehow, the brain trust aboard Oracle forgot this basic rule. So they rounded the mark and tacked all in the same maneuver, and in that moment they gave up their lead, Their thinking was that it was better to stay on the right hand side of the course to avoid the adverse current of the flood tide. Bad thinking. The first rule of yacht racing is to stay between your competition and the next mark. In a colossal brain-fade, the afterguard aboard Oracle ignored this rule and suffered the consequences. TNZ rounded the mark, hardened up on starboard tack and made short work of Oracles lead. At the first cross they were on port tack and ducked. On the next cross they were well ahead. After that there was no doubt as to who would win this race.

Ive sailed many thousands of miles as tactician and made more dumb moves than I can count, so I know how the crew of Oracle feels. In match racing it can be one bad move and your day is over, and if you still have several legs to race, that feeling of self inflicted wounds only grows. Oracle served this race up to the Kiwis on a silver platter and they knew it at the first cross, if not before. I can imagine the crew muttering under their breath as the were grinding in the sheets on that tack. Im sure the Kiwis were only too glad to snatch this race from the faltering grasp of the Yanks. It was so bad that Team Oracle decided to use their "postponement card" and skip race two today. Watching the body language on that boat, it was clear that this crew was demolished today, and it was probably a good decision for them to bail. Another pounding like that would have been devastating.

So the question is whether Team Oracle has it in them to come out on Thursday and make a race of it. I think this goes to the psychology of the game of yacht racing. Their boat is fast enough. Ive heard talk that its more complicated to sail than the Kiwi boat. Actually, all boats are more complicated to sail until the crew has practiced enough to make all the maneuvers look easy. If Oracle had another six months to sail the boat, all the maneuvers would go flawlessly. However, its possible that a demoralized crew can start thinking they are riding the slower horse and that can become a self fulfilling prophecy. If they dont fix that now, the crew will begin to expect the other guy to beat them. So the gang at Team Oracle needs to do three things if they want salvage this regatta:
1. Stop going the wrong way.
2. Keep the psychology of the crew from surrendering to defeat.
3. Make sure their strategy is one that can win, and make better tactical decisions.

Once again, I have to say that I am surprised at how tactics rather than simply nailing the start have been the deciding factor thus far in the regatta.

Installing a Chain Stopper

A while back I installed a Lewmar chain stopper on the foredeck to make anchoring a bit easier. It was a simple job to fashion a mounting block out of teak, make a backing plate out of apitong and bolt it all together. The job was done in a day. Then I went out and anchored and discovered that if I left it as is, the stopper would soon knock all the galvanizing off the chain. This is a standard flapper type chain stopper, rated at 5,000 lb SWL and sized for 5/16 chain. I had used this unit on my last boat, which had 1/4" chain and a vertical capstan windlass, and it worked well. The problem is that there is barely enough clearance in the stopper for the chain to pass through, and only if it is perfectly aligned and set at an angle that matches the angle of the chain as it passes from the windlass to the roller. On top of that, the deck in that area is only about half an inch thick. It is made of a fairly heavy fiberglass laminate and a bit of wood core.  This isnt really enough structure to simply throughbolt the stopper to, so I added a carbon fiber top plate and a larger wood backing plate to bring it up to snuff. The photos below outline the process.

Mold. 

First I measured the amount of crown in the deck forward of the anchor locker. Its nearly flat but I wanted the edges of the top plate to fit tightly to the deck so I created a bit of extra curvature in the mold, which is made of a piece of old 1/4" Starboard.

Paper pattern with pre-cut carbon fiber

I took a template off the deck and drew the shape in AutoCad. I wanted the top plate to be fairly large so I could attach it to the deck with several widely spaced fasteners to spread the loads out as much as possible. The rectangular shape is the outline of the teak mounting block.

Laminating the carbon fiber

I used four layers of Vectorply C-LT2200 carbon fiber cloth for the laminate. This fabric is made of carbon fiber bundles aligned along the 0 degree and 90 degree axes of the roll and stitched together. This architecture is stronger than traditional woven fabric. The four layers amounted to about 88 ounces/sq yd of material for a total thickness of about 3/16" when it was finished.

Second layer is rotated 45 degrees 

I oriented the first and fourth layers so the fibers run at 0 and 90 degrees to the centerline of the boat and rotated the second and third 45 degrees to provide strength in all directions. I used WEST systems resin which works really well for hand laminating projects.

Finishing the top plate

After the plate was laminated and cured, I glued another copy of the paper pattern to it so I could precisely locate all the holes. It was a simple matter to drill and countersink them exactly where they need to be.

Top plate ready for finish sanding and paint

Check fitting the hardware

Finished part installed

I made a backing plate out of 1" thick apitong that extends out to the bulwarks to help spread the loads as much as possible. The 10" cleat allows for a snubber to be run out over the port bow roller. I found that if I take a turn around the roller with the snubber, it wont jump off if it when the boat swings at anchor.

Chain and snubber geometry works

It took a couple of tries to get the alignment and angle of the stopper to match up perfectly with the chain. It would have been nice to have a larger stopper, but there was just enough clearance between the shank of the anchor and the hatch for this smaller unit.

55 LB Rocna just fits

Bulkhead 4 and First Gluing Disaster

Jeezum Crow.

First, Ive been having problems on the employment front that has been keeping me out of the workshop. Today, Im feeling good, confident, its raining, Ive got nothing else going on, so I roll into the shop and quickly pound out the framing for BH4. Then, I decide to start my first gluing.

Holy Baloney, what a disaster the whole thing turned into. First, I cover most everything with plastic. I set up my pumps, prime them, get my yogurt cups, my ziploc bags to deliver my epoxy to the wood Storer-style, etc etc etc. I got medium speed epoxy, so Im feeling pretty good and I go ahead and throw in a mess of pumps to the appropriate 2:1 ratio for the "Marinepoxy" brand that Im using. I decided to start out as clean as possible with the Duckflat method mentioned on Storers website, ie. mix everything in the ziploc bag. So I pour in the resin and hardener, I "massage" the bag to mix, then I start dumping some silica into it. For this part, I placed the bag over a yogurt cup. Interestingly enough, the level of epoxy in the bag continued to get lower and lower as I mixed in silica. A hole mysteriously appeared at the bottom. If this was a self-inflicted hole or a heat-inflicted hole, I dont know. Whilst I was investigating the bag dropped into the cup. At this point the mix just freaking took off temperature wise. "Whoa Nelly!" Batch One, done. I sat it aside and kept an eye on it so it didnt combust on my workbench.

Discouraged but not out, I mix up batch Two. This time, screw it, Im mixing in a cup, and Ill pour into a ziploc bag. The mixing goes well, I dump in the silica, that goes well. Its thick, but not super thick, definitely not peanut butter thick, but the temperature was starting to rise, and I wanted the epoxy delivered on the wood before it took off like the previous attempt. So into the bag, I cut the corner and that stuff just started pouring out all over the place. Then the bag got super hot, I dropped it, kicked it aside and starting grabbing the top and bottom frames for BH1. I placed them accordingly and clamped them down, but they started swimming all over the epoxy and wouldnt sit still. Epoxy was oozing out of every seam all over the place, I was watching two batches now for tell-tale smoking and potential combustion, and I was worried like the dickens that my frames were going to set akimbo.

Son of a bitch! Everything is somewhat quieted down now, and things are positioned somewhat where I want them, but not as perfect as I imagined. Im not down with the ziploc bag idea with the speed at which the epoxy starts to hyperventilate. Ive got to spread it over a larger area to mix and then either pour into a bag or distribute it over the surfaces with a different method. Im going to try the sidearms tonight just for fun, but after I calm down.

Edit: Some ideas on gluing better.

Mark the centerlines on the top and bottom frames to line up with the centerline on the BH in case everything goes to hell in a handbasket and the sidearms are removed.

Mix smaller batches, as in 2 pumps to 1 pump. Just keep it small and work from there.