Here is the stringer tabbed in place and you can see the corner box where two part foam will go. Since all the crap that was initially in the boat was taken out, the outer skin of the hull was not stiff, to correct this, we sandwiched 1/2" Divinycell between several layers of fiberglass, you see the end result here. The goal was reached, the floor is now stiff.
A bird's eye of the area that was completly wiped out and now is being rebuilt. Both stringers in place.
And the foam goes in and looks like this
After cutting the excess foam, sanding it, and filling the holes and gaps with plenty of cabosil (no bubbles) the next divinycell sheet goes in as double reinforcement. Actually everytime time we used divinycell, first went in a thick layer of cabosil and then the divinycell went in, we pressed it down to make the cabosil run thru the little holes and then wiped the excess.
Here is the easiest way to make the cabosil paste, with a cheap home made mixer and you have the paste in no time.
Change view, we were looking at the port side, this is the starboard side. After the divinycell of the floor is placed is covered with fiberglass. Next, the divinycell sheet goes in on the wall also as the core for this area was also taken out it had separated from the fiberglass.
Who noticed a small step on the bottom of the picture, right on the floor... well this is the 1st step in a 2 step process to make the engine mounts. This little step was made the same way as other things, a piece of wood was taped to the floor and foam was poured in. Foam was cut and sanded and then was covered with fiberglass.
A closeup of the divinycell so you can see how it's all buttered up.
After two layers of fiberglass of going all the way down.
After 4 layers of fiberglass going all the way down.
Here is another pix of the bench, here you can see the opening and the lip if you look closer
The helm being fiberglassed in, there was a gap between the helm and the wall so that was filled with foam, and so on... you now know...
My friend Craig came home to be with the family a couple days and he tested the bench along with Jenny my oldest. Craig is a big man, from this picture you can see you could fit 4 men in this bench if needed be.
The old supports for the floor made of wood came out, these were heavy suckers. These supports were replaced by "foam-filled-stringers", I'll call these floor stringers, they are so much lighter.
Here is how the area looked after being faired down.
Another mold was made for these floor stringers. This mold was made of melamine, so it was easy to take the parts off the mold. For these stringers I used only two 1708 layers.
Here is a couple of them, I made long floor stringers, then they were cut to size...
Second floor stringer going in.... I noticed after installing the first one that the stringer was warped, so I came up with this idea to properly align the stringer.
The 4th floor stringer going in.... I had to wait for the fiberglass to cure before removing my fixture and going to the next stringer installation. That brush is actually working as a support guys...
The 6th and last floor stringer going in... it took the whole day...
Going back to finish the engine mounts, the boat originally had aluminum plates in this area, I asked my mechanic and he told me to put them back in, so here they are going back in... gaps filled with cabosil and then the first layer of 1708 goes in
More cabosil and then another divinycell core goes in and is all finished again with more fiberglass, all of this layers will provide the height required by the engine.
Here is how it looks after the fiberglass layup is complete, notice how each layer is bigger than the previous one and at the end it reaches the centerline of the hull. You want to distribute the stress of the weight in this area as evenly as possible.
Here I'm making a couple of fiberglass forms needed to tie everything up, stringer to stringer, etc.
A support for the deck, again the foam + fiberglass drill.
1 1/2 inch pvc was used to make the rigging easier, the area where these pipes are visible from the deck were covered with foam and covered with two layers of mat. Here is how it looks when the foam was poured in.... BTW I had to use a syringe to pour the foam in as I had no space to work.
Here is the faired part
The captains seat fiberglass part is also a subwoofer cabinet, these two parts will make the proper size cabinet
Here is one part being tabbed into place and held by ingenuity ...
Here is the second part being tabbed into place. The wood piece helped align everything up. You can see in the second picture where the hole for the subwoofer will be made.
The sub's cabinet has to be enclosed so in order to install the captains seat part to the boat and to service the subwoofer a door was designed. This door needs a good seal so the woofer can make good sound.
Meet the captain / owner Mr. Axel Sparrow (my son), he sure made me shit my pants with his arsenal... He said I needed to finish his boat ASAP... or else...
I'll do a second post tonight...
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