Keel Fin Tool...

The boat will be getting a pre-preg carbon laminated fin with douglas fir shear web.  It is important for the keel fin to fit accurately into the keel box.  Gabe Murphy made a one-off tool for the keel fin using a CNC milling machine.   The keel fin will be laminated in this tool.  The tool has a left and a right side.  Here are the two blanks on the milling machine table.

Almost done.

The two halves have been milled and are now sealed.  The near end is the top and will form a taper to fit tightly in the keel box.  The bottom has a tab that fits into a socket in the lead keel bulb.

All finished and ready for the lay up.

Hull Strake #3 Starboard...

 

 Here are a few views with both of the #3 hull strakes wired in.

Inside of bow

Hull Strake #3 Port...

Eric, Joe, Anna, and I placed and tied the #3 hull strake, port side on Christmas Eve.

Cabin sole...

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Two cabin sole panels are being fitted here.

The cabin sole panels need to be supported from below.

 

The cabin sole panel supports are finished and the panels are ready to be skinned.

More progress on the motor well.

There are three web frames that support the upper hull and deck panels.  Here the two forward frames are being dry fitted.

The next pieces to be added will be the #3 hull strakes.

More Motor Well & Longitudinals...

More views of motor well parts being fitted.

The longitudinals have been trimmed to fit.  They are "skinned" on both sides with fiberglass cloth and epoxy on the table.

After sanding, the longitudinals are glued in place.

Fillets are made from epoxy thickened to the consistency of peanut butter with fillers.  The thickened epoxy is placed inside a quart sized plastic ziploc bag with one corner cut off and squeezed into the corners where the panels intersect.  A rounded stick smoothes the fillets.

Motor Well.

I have been working on the motor well while it is still easily accessible.  Soon it will be surrounded by other parts of the boat making it more difficult to work on.

The sides of the motor well plug have been fitted into the motor well.  Shims separate the plug sides from the well so that the plug will not fit too tightly in the well.

Plastic has been inserted into the saw cuts in the hull to isolate the epoxy gluing of the hull cutout to the sides making up the well plug.  After the glue cures, the remaining portions of the hull cutout were cut leaving this hole in the bottom of the boat.  

The hull piece that was cut out now forms the bottom of the motor well plug.

The plug will be filled with pour foam and will be capped by the motor well hatch in the cockpit sole.

Dry fitting of longitudinals...

Vacuum bagging a foam floor.

I was fortunate to find a used carbon fiber mast from a J/90, light and strong.  It turns out to have quite a history.  It is from Eye-Eye which was previously Surfinn.  Ryan Finn completed the Single Handed TransPac in 2004 in Surfinn with a corrected time of 11:06:11:30.

The longitudinals make up the fronts of the cockpit seats as well as the bunk fronts.  Here they are being dry-fitted against the hull and over the floors prior to gluing the puzzle joints.

The outboard motor goes through a well a few feet forward of the transom.  The cut out in the hull forms the bottom of a plug which goes into the motor well when the motor is stowed in a cockpit locker

There are watertight voids at both ends of the boat which can be accessed via 10" inspection plates.  The plates screw into their frames with a watertight o-ring seal.  Doubler  rings reinforce the bulkheads.