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KevFin

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Reply with quote  #61 
Lastly, Kevin McCracken fills some low spots in the wide trim.  "An ounce of prevention..."

-KevFin

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KevFin

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Reply with quote  #62 
Busy week here in the Belfry, bells ringing, bats flying... 

I missed photographing the rest of this weeks build up, but here at last are some pictures showing the first of the two side trim molds that will be made as it nears completion. 

The larger trim pieces used in it's construction are back on the deck. 

-KevFin

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KevFin

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Reply with quote  #63 
This newest mold sits atop it's wooden board on a set of 5 gallon buckets, a makeshift tabletop! 

Kevin works in the background sanding half of the hull mold.  He's on to the 120 grit, but that's another chapter!  We'll get back to it later.

Orange molds are piling up everywhere!

-KevFin

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KevFin

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Reply with quote  #64 
Here is a detail of the more complicated end of the mold.  The larger pieces had an overhang due to extra thickness which required extra care to fashion.  The backing board has an add-on tab as shown.

-KevFin

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KevFin

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Reply with quote  #65 
In the time honored tradition of two steps forward and one back we had a number of chips in the gel coat occur during the removal of the plugs (pieces being copied).  This is a common occurrence and will need to be repaired before the new parts can be made for Brad's boat.  You will notice some sanding is already underway.  This mold will need polishing as well before it is truly complete.

-KevFin

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KevFin

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Reply with quote  #66 
On goes a layer of fresh gel coat to fill in the chips.

Meanwhile a full size semi arrived this morning with the nicest looking shipping crate I've ever seen.  It took three of us to slide the 400 pound crate out of the truck and lower it down into my pickup.  Must be something interesting inside!  I'll have to open it tonight when I get off work.

-KevFin

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KevFin

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Reply with quote  #67 
Actually two crates in one, a left and a right, the pair were filled with windshields!  We have been waiting on these a long time.  The original set were badly damaged. 

I now have a set of four pieces and Brad has a set of four pieces. 

Fortunately, there are some flawed windshields as well, which will be used in altering the deck attachment area.  This will be a correction to the design that is yet to come as we get to work on the larger deck section.

-KevFin 

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KevFin

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Reply with quote  #68 
Getting to the bottom of things reveals a set of forms, the right one is shown in these pictures. 

This is attached to the bottom of the box and is made of sheet metal and chipboard with 2x4 bracing.  These serve as a sort of mold, once the plastic is heated it is draped over the form and allowed to cool.  A template was used to cut the plastic to shape beforehand.

These forms were shipped with the windshields as a type of support and packaging.  The remainder was then filled with heavy packaging paper, seen all around the truck in the photo above.

-KevFin

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KevFin

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Reply with quote  #69 
One set was made in clear like the original set.  The remainder were done in light smoke color. 

We felt that some of the original pictures of these boats fail to show the graceful shape of the Batmobile style windshields very well.

A light smoke color will be much better at showing the design.  A lot of pictures will surely be taken of Brads boat in the years to come.  It will be smart to have a set of windshields that show up better than the originals did.

-KevFin

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KevFin

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Reply with quote  #70 
It is a well worn cliche that, this car or that, is so nicely styled that it looks like it's moving when it is sitting still.

Well...

These windshields are so nicely styled that this concrete floor looks like it is moving when it is sitting still!

-KevFin

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KevFin

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Reply with quote  #71 
We're ending the week on a high note.   Just look at that shine!  This is the final polish on the motor-well mold.  Eventually all of the molds will shine like this.  

-KevFin 

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KevFin

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Reply with quote  #72 
Things are really starting to sparkle around here!  This is the long side trim mold after a great deal of elbow grease.  It is shown here with Stan and Kevin McCracken for scale.

-KevFin

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KevFin

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Reply with quote  #73 
The last time I saw the right hand hull mold it looked like this.  Kevin had just finished rough sanding the uppermost section with 80 grit.  The blue tape line marks an area where the contour changes along the keel.

-KevFin

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KevFin

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Reply with quote  #74 
Here is the same part after wet sanding multiple times using 120, 220, 360, 600, 1,000 and 1,200 grits. 

You can just make out the contour line in the lower picture splitting the square reflection.

-KevFin

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KevFin

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Reply with quote  #75 
Half of the fin mold is nearly polished as well. 

This was the Left hand fin that was molded and you will recall that it had to be extended in order to get away with making only one mold, to do both fins.

The second picture shows where some additional Gel Coat had to be applied to cover the extension seam.  This piece was molded from the inside half of the left fin. It will need additional work to catch it up to the outside half.

-KevFin

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