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KevFin

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Reply with quote  #76 
A close up of the right hand hull shows some very fine scratches remaining in the finish.  This is something that will be addressed before the first hull is made. 

You would be surprised just how hard it is to avoid any imperfections in a project of this scale. 

Wax and mold release agent would likely fill all but the worst of these, never-the-less, it was decided that additional polishing of these molds will need to be done.  Techniques are being refined in preparation for the polishing of the left hand side.

-KevFin

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KevFin

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Reply with quote  #77 
Another days work and no more scratches!  Just look at that shiny smooth surface!  The right hand side is finally finished and waiting on the left.

-KevFin

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KevFin

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Reply with quote  #78 
Skipping back and forth a bit, here is the section of fin mold that continues to be worked on. 

You can see that the add on section has now been sanded revealing a few spots still in need of attention. 

-KevFin

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KevFin

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Reply with quote  #79 
The long mold created a while back will make the four pieces of side trim, two in red and two in silver, but there are four additional pieces that cross over the deck. 

Here is the first of these being prepared for the mold making process.  It is being readied with the addition of carefully positioned "dam lines". 

The cardboard divides the mold in a logical place since this mold will need to be created from more than one piece due to the complex shape.

-KevFin

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KevFin

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Reply with quote  #80 
In other news today...

The left hand, hull mold half, has been finished on the bottom and has been turned on its side for further sanding.  By turning the side down that is being worked on, it prevents the file board (and other devices) from having to be held up at arms length which is very fatiguing.

The second picture shows within the oval outline an area of fine sanding dust that has yet to be blown off.  This dust gets everywhere, hair, cloths, floor, other molds.  The whole building fills up with it.

Not visible in this shot is an area at the bow where the gel coat is getting thin again.  It will need one more layer there, which will be re-sanded this evening, before moving on to finer grits.  Right now 80 grit is being used.

-KevFin

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KevFin

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Reply with quote  #81 
Here's that last fin mold half once again.  It has been sanded and re-gelcoated and sanded some more.  Now all the imperfections are gone.  As the grit gets finer the finish looks smoother and smoother!  It's nearly ready for the final polish now!

-KevFin

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KevFin

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Reply with quote  #82 
This is the last of the work being done on the left hand section of hull mold.  It is being blocked out for the last time using 80 grit.  From there finer and finer grits will be used, all of them with water.  It will be polished fairly soon now and the first hull can finally be laid up!

The second photo shows a smaller air tool being used than before.  This size is necessary due to the curvature in this bow area.  It requires a great deal of skill to avoid dimples when using smaller sanders like this.

-KevFin

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KevFin

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Reply with quote  #83 
I wanted to post a picture of the final hull section polished to a glossy shine. 

Whoops!  It's farther along than that now!  The glossy shine is upside down.  The hull mold is now completely finished and has eight coats of a special wax on it! 

It is fully assembled and inverted to prevent dust from settling.  The room is being cleaned and tomorrow the Gel Coat will be ordered.  The mold is finally ready to produce it's first hull and this phase should begin later next week with the arrival of the color. 

Pictures of the inside of the shiny hull mold will be taken before the color goes in and the whole process will be captured as it happens right here.  So stay tuned, same boat time, same boat channel!

-KevFin

 

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KevFin

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Reply with quote  #84 
As the drama above unfolds, work continues on the last of the trim molds, while behind the scenes plans and preparations are being made to start the deck mold construction. 

That section promises to be a large project it's self and will require a three piece mold. 

Here now, you can see the gel coat is all in place awaiting the trim mold build up, which will advance one hand laid layer at a time.

-KevFin

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KevFin

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Reply with quote  #85 
Just when you thought we were running out of things to mold!  Isn't there a hatch cover we can copy?!

-KevFin

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KevFin

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Reply with quote  #86 
You know how this works by now, the hatch was removed and the aluminum strips taken off.  Then it was thoroughly cleaned and sanded, covered with mold release and sprayed with gel coat. 

Here it is shown with layer after layer of mat being applied.

-KevFin

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KevFin

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Reply with quote  #87 
Allow some time to cure before removing the plug, or hatch cover...

-KevFin

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KevFin

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Reply with quote  #88 
...and presto!

Fin Girl, AKA Quality Control, looks pleased with the freshly harvested mold. 

That's yet another item to add to the dreaded; block sand and polish pile.

-KevFin

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KevFin

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Reply with quote  #89 
Hey!  This "JUST SPLASH A MOLD AND POP OUT A FEW COPIES", thing...

...this is HARD! 


-KevFin

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KevFin

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Reply with quote  #90 
These postings have been going on a long time.  They represent eight hour days, forty hour work weeks, month after month. 

This project was well underway before I even started putting it up on the forum and that main deck is going to be a bear!

Whew!  Good work guys.  "Are we there yet?"

-KevFin

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