Filleting Fairing and Sheathing

Three months have now past since we turned the boat over, but despite being continually busy I have still managed to spend a further 266 hours on the build. The following blogs will record this work in chronological order.

With the colder winter months looming ever closer, I felt the need to complete the filleting and fairing as soon as possible to take advantage of the relatively mild temperatures. Cold weather would significantly affect the setting time and work-ability of the epoxy. At all junctions between the transverse and longitudinal bulkheads, planking and transom, planking and backbone, I first wetted the joints out then applied a 20mm radius fillet of epoxy mixed with a wood flour blend. When set I covered these with 100mm wide 300 gsm woven fibreglass tape. Once the epoxy had hardened I cleaned up the fillets and then applied a filler of epoxy mixed with Phenolic micro-balloons fairing the surface of the tape and blending with the surrounding surfaces. All areas were then rubbed down and blended in smooth. This operation took a considerable amount of material and time, particularly the rubbing down. As per the architect’s recommendation, I sheathed the inner side of the garboard and the first strake throughout the boat to provide additional stiffness, this produces an immensely strong and relatively maintenance free hull which is of particular importance in the difficult or inaccessible areas. I decided not to fill and fair the unseen areas beneath the berth soles or floor boards, I just cleaned and rubbed them down leaving a fair surface which will be painted later. 

20mm radius epoxy fillets sheathed and faired at all joints.

The berth soles are designed to be shaped to sit on the hull planking to provide support along the outer edges. This I did but in addition installed shaped plywood supports glued in place and filleted beneath with an epoxy wood flour blend mix. Although a little time consuming, this provided further stiffening of the hull and gave a really solid base for the berth sole boards.

The additional berth supports were made up by gluing 2no strips of plywood, shaped to fit the hull then glued in place. When set an epoxy fillet was applied to the void beneath. This is also a good example of the rubbed down sheathing beneath each berth which will be finished in locker paint.

Filleting and sheathing beneath the cockpit floor. This and other areas will be difficult to access once sealed, I therefore intend to apply the full paint regime before closing off. Note the water tight hatches  giving access from the side lockers to the void beneath the cockpit floor.  The cut outs in the transverse bulkheads are to allow storage of oars and the balloon jib pole  etc.