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After turning the boat over
last December 2001, the first order of business was to sand away the squeeze
out left from bonding the bottom plywood. This turned out to be a larger
job than I had planned, considering there are 16 battens across the bottom!!
Even after using an extra slow hardener, couldn’t get it all removed before
curing. Splitting time up between sanding; the engine compartment metal
was cleaned up, new lifting eyes machined and all bonded into the hull. |
The original boat had a steel
rudder and strut reinforcement that was too badly rusted to reuse. I made
up a new one from some aluminum plate. The welding didn’t go too good and
the whole thing was badly distorted, I’ll have to cut it apart and find
a better welder.
Steering box was rebuilt and
the other metal parts were made ready to install. |
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The entire hull was cleaned
and wiped down; two coats of CPES were applied to seal everything up. This
sealer really soaks into the wood, especially on the end grain. It works
the same as an epoxy primer and is compatible with varnish or other epoxy
surface finishes. CPES is a solvent based product so make sure a respirator
is used. |
| The sponsons have been a major
question mark since this project was started. They had completely rotted
off the boat, and had been modified from the original design about 1967.
After exhausting sources from former crew members, Ray Dong agreed to meet
with Ron Jones Sr. Several people had stated that the ’67 sponsons
were very similar to those on the early Jones cabovers. Ron’s thoughts
and recollections were noted. This information and data from plans were
fed into a computer by Randy Linn (Linn Racing) and we had a design. Major
changes were in dihedral and angle of attack. The longitudinal step in
the running surface was also eliminated. Hindsight wise, building frames
directly from this information isn’t the best way to go. Building frames
from some inexpensive material and mocking them up on the boat would have
saved time, money and aggravation. There were problems getting a fair line
on the shear, several frames had to be adjusted to correct the line. I
now have a large expensive pile of useless frames!! |
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| The last two frames were bonded
to an aluminum pan to carry the loads back into the hull. Laminated the
shear batten in three pieces, one 3/4 piece of lumber wouldn’t make the
curve at the nose without breaking. I was glad that the boat was right
side, up made the job of fastening the frames easier and also visualizing
the shear batten line. |
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December 5 was turn over day.
This went pretty good considering an eight foot wide boat in a nine foot
high garage!! It took four of us with the help of an overhead hoist. She
went back on the original jig.
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Frames were faired as the
rear 32 inches is perfectly flat and to allow full contact with battens
as they curve to the bow. Sponson battens are being installed in this view.
Again the battens were split lengthwise into two ¾ square pieces
to allow for the twist as they head to the front. No permanent fasteners
were used. Screws that run thru the aluminum runner and plywood into the
framing will be installed later. It’s difficult to visualize how the running
surface and side of the sponson run out into the nose of the boat. I positioned
the bottom shear where it looked right. Later, had to cut it loose and
reposition at the bow. Only one side of boat was built at a time to avoid
multiple mistakes. |
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Started
fairing the side of sponson from rear carrying it forward, the running
surface was done by the same method. I think it gives a sight line and
a flat surface to work from. A long straightedge helps a lot.
| The air trap lumber was fitted
and bonded in, followed by its 6mm plywood facing. Scribing and fitting
these pieces to the bottom profile of the boat took quite some time. The
side plywood was roughed in and bonded, screws were removed just before
the epoxy cured…don’t get caught sleeping!! A final fairing of the
running surface and the deck shear and we’re ready for the running surface.
Planning on framing other sponson before covering this one, will be able
to transfer dimensions etc. |
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Motor is also being prepared.......more
to follow.
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