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4. SECTION 6 Page 5 0257 continued B Preparing the Surface EN Remove as much of the wrinkled area as possible with a putty knife 2 Remove the rest of the wrinkled area by block sanding smoothly with 100 grit sandpaper 3 Clean the area thoroughly with a white cloth saturated with acetone C2 Preparing the Patch d Make a smooth thick manageable putty by mixing Cab o sil and a matching gel coat Mix thoroughly until all lumps have been removed IMPORTANT if all lumps are not removed from the putty they will trap air that in turn will leave tiny pin holes in the area being patched The appear as white spots in the patched area lumps also will 2 Add catalyst to the putty in accordance with the that no with to to remove the area For manufacturer s instructions Mix thoroughly so uncured spots will occur in the patched area Applying the Patch d Apply the putty smoothly over the damaged area a rubber squeegee 2 Cover the area with cellophane and allow putty cure Sanding the Patch Block sand the patched area with 100 grit sandpaper excess putty and to restore the original contour of Spraying the Patch Spray finish the patched area with a matching color the proper finishing procedure see Section 6 4 SECTION 6 Page 6 6 3 FRACTURE AND PUNCTURE REPAIRS Basic Procedures for Repairing 21 Fractures and Punctures The purpose
5. SECTION 2 5 LY CO Page RICHMOND SUPPI Chula Vista Ca MARCO CHEMICAL COMPANY 1020 44th Street Norfolk Va hardware Blvd RESIN Carolina Conn ES W Local marine BRAHAM INDUSTRIES 1249 W Katella Orange Calif EMPIRE MACHINERY Virginia Beach orfolk Va CHEMICAL RA 210 E Alondra Gardena Ca OIR COATINGS amp LCOX CRITTENDEN OGRAM INDUSTRI 7j Lenoir North WI Middleton MO 6357 Arizona Circle Ca 90045 ENSEN Los Angeles JOHANSEN amp CHRIST 898 W 16th Stree Costa Mesa Cas CORP Virginia RUBBER treet Calif hardware COLUMBIA YACHT I Portsmouth INDUSTRIAL HOSE amp 2816 E S Los Angeles ENYON MARINE K Guilford Conn Local marine 2 6 continued FIBERGLASS MAT CLOTH WOVEN ROVING GATE VALVES GEL COATS SELF CONTAINED ERS DUCTALL BEADS HEADS HEADLIN HOSE SECTION 2 Page 6 R C MARINE 17422 Armstrong Santa Ana Calif LOOS amp CO Ponfrett Conn WILCOX CRITTEN Guilford Conn HOOD INDUSTRIES Bakersfield Calif Local marine hardware VOLT 2364 E 128 th Compton Calif ij SWING AWAY Wesley Street Portsmouth Va Local marine hardware
6. ANIHdHY3312 HOOOL ON NO 4 lt 3 2 Ce AOC vice gana EEYCZIT lO E NOR jd L M j vacui 3 TEMES i S Ee om MOG Ec 7 WNT AOL 92 2222 222 OMO TISTE MOG 65 s 2 72 1 ap eie se TT YA E pup m 4 a S EPP 28 0 P e AA 0 8 03 00 BaF ASS Y 622 POU R OPP MOC PUES uA coez 7 GIF 2 MSS T 51 0 20m VWO AME Que SUME WO DACOLT SW SPC AC PUC IO COD 229 EKIB 2 P Wit TA fe E 2 YEP 6 50 co007 YZGWON 66 SPOS PEWS DUD Y 07 27 2 72 O2 F P 2 na
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8. Glass is a combination of several common raw materials such as silica sand line and alumina plus small percentages of other elements Among known solid materials glass is unique in that it has no detectable crystalline structure It is essentially a supercooled liquid of immeasurably high viscosity and surface tension Glass potentially has very high strength This is one reason it is produced in fibers that are then combined to form the tough high impact strength material known as fiber glass and used as a reinforcement for plastics On a pound for pound basis glass fibers are actually stronger and stiffer than steel E glass fibers are the most common in use today because of their low cast and good fiber forming characteristics strength and electrical properties Glass fibers normally have a sizing coating applied during their manufacture There are various types of sizings but all have some common purposes 1 to bind mono filaments together into a more easily handled fiber called a strand 2 to lubricate monofilaments so that they do not abrade and break each other and thus cause reduced strand strength and 3 to promote surface contact between the fiber and the laminating resin that is to increase fiber wettability Special purpose sizings are sometimes applied to alter the properties of the glass fibers 6 1 2 Forms of Commercial Glass Fiber Glass fiber materials are supplied commercially in the form
9. Mix thoroughly until all lumps have been removed SECTION 6 Page 9 continued 2i IMPORTANT if all lumps are not removed from the putty they will trap air that in turn will leave tiny pin holes in the area being patched The lumps also will appear as white spots in the patched area Add catalyst to the putty in accordance with the Mix thoroughly so that no manufacturer s instructions uncured spots will occur in the patched area Apply the putty to the ripples and indentations as Procedure D Steps 2 instructed in Section 6 3 through 6 Sand the patched area as instructed in Chapter 6 3 Procedure E Buff the patched area as instructed in Section 6 3 Procedure Spray finish the area with a matching color as instructed in Procedure D below and in Section 6 9 all necessary repairs to the that is the area has been fracture into the fiber ripples and indentations repaired area with a matching color For the proper finishing procedures 5 Section 6 9 MATERIALS Acetone Gelcoat Cab o sil Catalyst Sandpaper 100 grit Cellophane been completed 2 Spraying the Repaired Area This procedure applies only when crazed area hav sanded any craze extending as a glass has been repaired and any have been patched Spray finish th Repairing Gel Coat Wrinkling TOOLS White cloth Sanding block Putty Knife Rubber Squeegee NOTE 6 2
10. Perkins Marine Miami Florida Brush Lumber 7653 Telegraph ontebello Calif HOUSE OF HARDWOOD W Los Angeles Calif SPAR LUMBER 1325 Harbor Long Beach Calif DEAN HARDWOODS 3701 Elm Portsmouth Va continued ES amp GATES 2 6 LIFELIN LIFELINE WIRE PELICAN HOOKS amp FITTINGS LIGHTS INTERIOR FIXTURES TS RUNNING NAVIGATING EAK ER T LIGH LIGHTS LUMB SECTION 2 Page 7 THOMPSON MAHOGANY 7400 Edmund Philadelphia Pa BRUSH LUMBER 7653 Telegraph Montebello Calif SPAR LUMBER CO 1325 Harbor Long Beach Calif U S PLYWOOD 2662 E Del Amo Blvd Compton Calif 90224 STEWART PLYWOOD 14051 So Marquardt Santa Fe Springs Ca U S PLYWOOD Ingleside Rd orfolk Virginia ENOIR COATINGS amp RESIN Lenoir North Carolina ERSKINE JOHNS 4677 Worth Los Angeles Calif Local marine hardware Crystalliner 1626 Placentia Costa Mesa Calif x 1 1018 COATINGS amp RESIN Lenoir North Carolina SALISBURY RUBBER 401 No Morgan Chicago Illinois INTERNATIONAL PAINT CO 508 N Beacon San Pedro Ca Local paint store Local marine hardware LUMBER MAHOGANY PLYWOOD MEK CATALYST HARDENER MICRO BALLOONS MUFFLER PAINT VARNISH Section 2 Page 8 11018 CO
11. The first step in constructing the wooden interior is to install the cabin sole and the floor timbers which support it Install them in the location shown in the Hull Assembly drawing Make sure there is drainage through all of the floor timbers so that water can run from all compartments to the bilge sump If necessary cut limber holes at least 3 4 diameter to provide drainage The cabin sole can now be cut and mitered to fit the slope of the hull When everything is ready a small amount of rather thick micro balloon filled resin should be prepared and spread on the hull in the area where the sole will rest Smooth out the micro balloon filled resin with a trowel or squeegee making a smooth transition from the sole to the hull then when it is cured bond the sole to the hull with two layers of 3 oz mat and one layer of 7 1 2 oz cloth SECTION 5 Page 2 Sad continued With the sole in place proceed to cut and fit the bulkheads V berths and your other cabinets Some of the remaining interior woodwork can also be cut and fitted at this time However depending on the location of thru hulls bulkheads etc the finished pieces should probably be set aside and only bonded to the hull in the proper sequence with the hull to deck joint chainplate installation and plumbing and electrical installations 5 eel Tools Required In order to do a workmanlike job on your boat you will need certain hand tools and p
12. leans Excess sealer should be cleaned before it cures RIVETING The rivet spacing should be 3 apart When double lowers are used the rivets should be 1 to 1 1 2 apart 2 forward of forward lower to 2 aft of aft lower 5 22 Hull Deck Joint without H Metal Trim the flange on the hull down to 1 1 2 overall except at the bow where you should make a template of the underside of the deck flange from the bow to 3 aft both port and starboard Transfer these lines to the hull flanges and trim to the line Grind off the seam at the bow and stern so the deck will set down evenly Trim the flange on the deck down to 1 1 2 overall in width and then route the flange to 1 4 thick At the bow you will have to make a template of the outside of the hull and transfer this to the deck before trimming the forward most three feet both port and starboard SECTION 5 Page 7 2 HULL TO DECK JOINTS 5 2 2 continued Set deck on hull First set in engine heat riser and fuel tank Clamp the deck and the hull together in about six points on both sides Starting with the transom and working forward evenly on both sides drill and countersink screw holes through the deck flange and hull flange clamping the hull and deck together in a fair line as you go Use a flathead 8 self tapping screw to pull the deck and hull flange together Space these 8 10 inches apart Clean the inside of the joint using A
13. Fractures From Outside the Structure Only TOOLS MATERIALS Power sander Scissors Gelcoat 24 grit sanding disc Stirring stick Cab o sil sanding block Paintbrush Cardboard Rubber squeegee White cloth Acetone Putty knife Cellophane Fiberglass clo Fiberglass mat Resin Catalyst Sandpaper 50 6 100 grit 6 3 NOT 6 3 SECTION 6 Page 22 6 3 9 continued B Repair Procedure When a compound fiber glass fracture is accessible only from the outside of the structure repair it as instructed in Section 6 3 Procedures C through H However when removing the damaged fiber glass initially with the power sander Procedure C Step 1 in Section 6 3 do not sand all the way through the structure so that a hole is formed Leave just enough damaged material to serve as a backing for the patch 66345 Repairing Punctures From Outside and Inside The Structure TOOLS MATERIALS Power Sander Fiber glass mat 24 grit sanding disc Fiber glass cloth Sanding block Resin Rubber squeegee Catalyst Putty knife Sandpaper 50 100 grit scissors Gelcoat Stirring stick Cab o sil Paintbrush Cardboard White cloth Acetone Cellophane Woven Roving Masking Tape NOTE A puncture is a hole that goes all the way through the fiber glass structure being repaired When the hol is accessible from both outside and inside the structure repair it as instructed in this chapter beginning on the outside Procedure H below H Repai
14. deck a short piece of H metal shall be slid along the joint of both the deck and the hull to insure the H metal will fit The bottom of the H metal shall be filled half way up with a polysulphide sealant such as Nauti calk and placed on the hull within one half hour Care must be taken to insure that the sealant does not fall out When the H metal is pressed down on the hull edge the sealant should ooze out The top of the H metal shall be filled half way up with Nauti calk Within one half hour the deck shall be placed on the hull and forced down into the H metal When the deck is pressed into the H metal sealant should ooze out When riveting place rivets 3 apart When double lowers are used th rivet spacing shall be 1 1 2 from two feet forward of the forward lower to two feet aft of the aft lower Clean the H metal within two hours and seal rivet heads The open corners at the transom and the bow between the H metal shall be bonded with 4 oz of mat and one layer of 3 oz cloth After installing corner and bow castings a fillet of sealant shall be wiped between the H metal and the fiberglass above and below the H metal and the castings The headliner and deck shall be bonded in the deck mold After trimming the outer and inner gel face should be sanded off 1 2 from the edge the full length on both sides and across the transom The hull liner will be placed accurately in the hull while the hull is still in
15. i i p nee I r NN A POP ien ER mn Au SH I f 6 0 22 7 CU AME FOS ONAR Day 9 SEXE PBRLS AMAT 1 5 2 0 2 25 ONIMVHO 60351 38 AA 2 STE 2 SS Bere HANNON 76 DOM A2 SPOOF PHASE p DAPIT F FOL TUAM VIO duum VOLS p POLS e 0 i DU 5 Bue fe p hui 2085 A NI SOR NEDY IIOS THIT SD PION EU SB 6 2 79 232 7 7 ZA MO l 78 755 7 667 VOT INIA 33 POTI 20 77 Ab 20 3 7 MLIMA 2 WVO 377 3 774 704 0 2 TLV 4 87 SS OS 5 T4NW LAVHS VAN OA OL NOREHGY 3 Ol 10 36 xii 3 8 ISAW GOu FONE 2 ONAN OW av
16. mast head fall off slightly to leeward giving the mast a smooth even curve from head to deck In a tall rig the intermediates play an important part in controlling the upper mast section and this will be especially noticeable in stronger wind conditions After a few more sails in strong breezes the rigging should be checked again for tune as additional stretch will occur Backstays 2 When racing the backstay may be tightened to compensate for extra forward loading applied by the Genoa At the conculsion of the race it is very important to slack off the amount you took up on the backstay turnbuckle as this avoids setting up unnecessary strains on the hull and rig Since you want to keep the mast straight while racing you will probably tighten up on the jib stay first so when the backstay is slacked off the mast head will hook slightly forward When the backstay is tightened up this hook will disappear and the mast will be straight Too much tension on the backstay is probably the prime reason for mast and rigging failure It has been found that tension in the backstay can increase 1608 to 2008 due to the wind load on the headsail and dynamic loading due to heavy seas With the optional hydraulic type adjusters tension can easily be applied far beyond that which is necessary or safe The tension on a shroud oz stay should not exceed 258 to 308 of the cable s breaking strength at the outside limit Below are the breaking str
17. o roving woven roving and cloth Another form is milled fibers which aremixed with resin to serve as a filler and stiffener in patching putty 623 Resins Glass fiber materials are laminated with plastic resins to form fiber glass reinforced plastic products such as boats and automobiles Commercially available laminating resins are synthetic polymers of a class called polyesters Most SECTION 6 Page 2 6 1 3 continued are soluble in styrene monomers and are in fact sold as solid resins dissolved in styrene monomer Special purpose resins can be made fire retardant flexible thixotropic slow to drain off a vertical surface or corrosion resistant to name just a few Polyester resins vary considerably in their physical properties after cure That is why it is important to select the proper resin for each of the many fiber glass products now being manufactured 6 1 4 Catalysts Promoters and Polymerization Polyester resins have to be cured before they can be useful to a manufacturer of fiber glass products The curing process is a chemical reaction called polymerization Chemically this word implies the buildup of large groups of molecules held together by chemical bonds If many molecules group together in this fashion the resulting product is a hard rigid solid that assumes the shape of its container For all practical purposes the container is called a mold and the polymerization is called gellati
18. of this chapter is to give you the basic procedures for repairing fractures and punctures holes in the fiber glass that is below the gel coat surface of a fiber glass product or part Sections 6 3 2 thru 6 3 7 give specific variations in the basic procedures according to the type of fracture or hole IMPORTANT To determine how to repair a fracture or puncture refer first to the appropriate section Fractures are classified as 1 simple fractures which do not penetrate the fiber glass structure and 2 compound fractures which do penetrate the structure but which can be reached from both outside and inside the structure Section 6 3 3 or only from the outside Section 6 3 4 Punctures are classified as 1 holes that can be reached from both inside and outside the structure 6 3 5 or only from the outside of the structure 6 3 6 and 2 holes that are larger than 1 4 inch 6 3 7 TOOLS MATERIALS Power sander Fiber glass mat 24 grit sanding disc Fiber glass cloth Sanding block Resin Rubber squeegee Catalyst Putty knife Sandpaper 50 amp 100 grit Scissors Gel coat Stirring stick Cab o sil collodial silica Paintbrush Cardboard White cloth Acetone Cellophane Woven roving Wire Masking tape Stick Milled fibers Ba Removing Damaged Fiber Glass 1 Remove the damaged fiber glass from the fractured area or puncture with a power sander and 24 grit sanding disc To restore the strength to the damaged area you must sand outw
19. the keel With double lowers the after lowers will be looser than the forward lowers by about 1 of play Some of the newer tall rigs have intermediate shrouds the tension of which should be between that of the uppers and lowers On a large mast you may notice a line of rivet heads running up one side of the mast These hold a 3 4 PVC tube to the inside of the mast for the running of optional instrument wires The final tuning of the mast should take place while sailing to windward in a medium breeze of 8 to 10 knots Sighting along the backside of the mast from deck level will indicate what further turnbuckle adjustment needs to be made to the WINDWARD side of the mast The top of the mast SHOULD NOT hook to windward In a medium breeze the mast should be straight and this is normally accomplished by taking up on the lower shrouds ALWAYS TACK and then make the turnbuckle adjustments on the now L or slack side of the mast and then sight the mast on the new SECTION 6 Page 33 continued windward side for further corrections After a few tacks the mast should be straight Secure the rigging by in serting cotterkeys into the turnbuckles spread them open and cover with tape to prevent any snags Special attention should be given to the initial stretch of the rigging especially after the first sail in a strong breeze In windy conditions it is actually desirable to have the
20. with respect to the hull measure from the aft tip of the keel to the bottom of the boot top on either side These two dimensions should be equal within 1 2 If these two dimensions are more than 1 2 shims shall be used made of Stainless steel strip running the full length of the keel This shim must be completely encased in the Epibond 150AB when the keel is fitted to the hull Remove keel from keel pocket and sand keel pocket and sides to roughen surface and remove gelcoat Apply to the top of the flange to the keel 1 2 coating of Furane Epibond 150 A B which has been mixed ina 1 to 1 ratio in accordance with the manufacturer s recommendations e 22 6 Fit keel to keel pocket by resting the entire weight of the boat on the keel SECTION 5 Page 5 Keeling Procedure SEEN Wrap keel bolts with caulking cotton and apply PRC 5000 Nauti calk may be substituted for PRC 5000 to the bolts on the inside of the boat Place keel bolt back up channel over bolts and tighten keel by using a flat washer lock washer and nut on each bolt Nuts should be tightened with a 16 lever arm 5 8 9 The Furane Eipbond 150 A B has a three hour working life Be sure to fill the gap between the hull pocket and the keel and clean all excess Epibond 150 A B within three hours The boat should not be put in the water before the 72 hour cure has been completed 5 8 10 The Epibond 150 A B should be
21. 6 Owner s Manual Coronado 25 0 TABLE OF CONTENTS INTRODUCTIO BILL OF MATERIAL DEFINED AND EXPLAINED Fiberglass Resins amp Catalysts Gelcoat Marine Wood Products Fasteners Suppliers and Vendor List TECHNIQUES Gelcoat Touch up and Repair Micro Balloon Filled Resin Bonding Cutting Drilling and Grinding Winterization Anti fouling Protective Coating BLUEPRINTS AND DRAWINGS INSTALLATION OF COMPONENT KITS General Assembly Instructions sd Tools Required Keelingand Leveling Hull Temporary Cover Over Work Area Importance of Leveling Order of Assembly ajo ele NOB WIN WIN OT G1 NM ECTION CTION ECTION ECTION ECTION n Hull Deck Joints Bx Hull Deck Joint with H Metal S mor Hull Deck Joint without H Metal Bulkheads and Structural Woodwork Engine and Fuel Tanks Thru Hull Installations Chainplates Rudder Assembly Keeling Procedure Plumbing and Water Tanks Stove and Tank Installation Windows Deck Hardware Exterior wood Electrical System Cabinetry and Interior Wood Spars and Rigging Launching and Commissioning FIBERGLASS REPAIR ntroducti
22. 6 1 5 continued Fibers of the reinforcing material acts as a barrier to liquids and limits degradation that may result from ultraviolet radiation It also eliminates the need for painting the product after it has been built Although the gel coat is on the top or surface of the fiber glass product it is applied first during its construction usually by spraying it on the walls of the mold The remaining fiber glass reinforcements ar then laminated onto the gel coat permanently bonding it to the molded product Gelcoats consist of a complex mixture of several materials including a curable polyester resin a colorant and a catalyst which are formulated according to Specific requirements 6 1 6 Fiber Glass Laminates Glass fibers reinforce polyester resins much like steel rods or mesh reinforces concrete In both instances the more reinforcement you add the higher the breaking force of the end product but only up to a point After that point has been reached the breaking force remains about the same but the strength pounds per square inch actually decreases For glass fiber polyester resin laminates however the percentage of glass fibers is usually limited by other factors such as economics and workability For instance manufacturers of fiber glass boats make their laminates just slightly stronger than what is required for normal safety considerations The current practice is to add from 25 to 40 percent glass by wei
23. ATINGS amp RESIN Lenoir North Carolina RAM CHEMICAL 210 E Alondra Gardena Calif Local marine hardware COLUMBIAN BRONZ Freeport Long Island New York AAA Propeller Service 127 Industrial Way Costa Mesa Calif RULE INDUSTRIES Cape Anne Industrial Park Glouscester ass HARRIS MARINE 1308 Logan Costa Mesa Calif 152 BALBOA MARINE HARDWAR Newport Beach Calif CRYSTALINER 1626 Placentia Costa Mesa Ca 11018 COATINGS amp RESIN Lenoir a ALLIED METAL HOSE CO 3746 Ninth Street Long Island City N Y PLETZ BROS Industrial Park orfolk Va Local Sears amp Roebuck Local builders supply RESIN Bronze POLYESTER PROPELLER PULPITS Bow amp Stern Exhaust Flex Coupling EY ELL RELEASE ANKLE B SABER SAW BLAD SECTION 2 Page 9 ITT HARPER 7307 Pulaski Hwy Baltimore Md LAVENDAR FASTENERS 884 W 18th St Costa Mesa Ca Local marine hardware VOLRATH Sheybogan Wisc Ziegler Harris 11341 San Fernando Rd San Fernando Ca Local marine hardware GALLEY MAID P O B 10417 Riviera Beach Fla KENYON MARINE GUILFORD CONN Local marine hardware TECSTAR INC 16550 N W loth Miami Fla Vic Berry 2527 W Coast Hwy Newport Bea
24. Deck Hardware The stem fitting is bolted through the deck and the outside of the hull using stainless steel flat head bolts of the proper size with flat and lock washers and nuts on the inside of the hull and deck Use a liberal amount of sealant around the bolts and under the stem fitting plate on deck The bow block on deck must be notched out the width of the stem fitting strap so that the stem fitting is flush against the bow The backstay chainplate is mounted either through the deck at the transom ox on the transom depending upon the Sailcrafter model you are building Use round head stainless steel bolts of the proper size and length with nuts lockwashers and flat washers The Deck Assembly drawing will give you the proper location A gusset is bonded to the inside of the transom with the same bond as was used on the chainplate bulkheads when the chainplate goes through the deck The plywood gusset is offset from the centerline to port 7 16 to allow for the 1 4 bond over the plywood gusset and this will put the center of the backstay chainplate on the centerline of the deck The centerline of the upper hole in the backstay must be 3 above the deck and on the proper angle in line with the backstay to the top of the mast so that there is a straight pull on the plate Mount all other hardware in accordance with the deck assembly drawing Be sure to use either back up plates or a large flat washer under all hardware
25. Patch See Section 6 2 Procedure E F Buffing the Patch See Section 6 2 Procedure F G Spraying the Patch If the gel coat has been sanded through during Procedure E above that is the fiber glass is visible you must spray the area with a finishing coat For the proper finishing procedures s Section 6 9 SECTION 6 Page 2 64 25 Repairing Nicks and Small Holes TOOLS MATERIALS Heavy duty polisher Harsh grit buffing compound Huffing pad for polisher Acetone white cloth 2 Water Sanding block Gel Coat Putty Knife Catalyst Cellophane Milled fibers Single edge razor Sandpaper 200 900 amp 600 grit e Preparing the Surface Remove the damaged material from the nick or small hole with the edge of a putty knife 2 Clean the damaged area thoroughly with a white cloth saturated with acetone om Preparing the Patch ls Make a thick creamy manageable putty by mixing equal amounts of milled fibers and a matching gel coat 2 Add catalyst to the putty in accordance with the manufacturer s instructions and mix thoroughly D Patching the Nicks and Small Holes See Section 6 2 Procedure D Steps 2 thru 6 E Sanding the Patch See Section 6 2 Procedure ti ES Buffing the Patch See Section 6 2 Procedure F G Spraying the Patch If the milled fibers in the patch affect the color of the gel coat so that the color does not match that of the unit being repaired you sho
26. Procedure C Step 1 above 2 If the patch applied to the outside of the structure in Procedure D above CANNOT be seen from inside the structure for example it is behind the instrument panel of a boat complete the inside repair as instructed in Procedure G below 3 If the patch CAN be seen from inside the structure complete the inside repair as instructed in Procedure H below t SECTION 6 Page 9 05337 continued G Repairing Hole That Cannot Be Seen Inside the Structure d Feather the area thoroughly with a sanding block and 50 grit sandpaper Dis Clean the area with a white cloth saturated with acetone Su Cut one piece of fiber glass mat that completely overlaps the hole filled with the back up patch of catalyzed resin and milled fibers at least 1 inch 4 Make a mixture of resin and catalyst with a stirring stick in accordance with the manufacturer s instructions Mix thoroughly to prevent uncured spots 55 On a piece of cardboard and using a paintbrush wet out the piece of mat with the catalyzed resin 6 Apply the piece of mat over the hole Remove air bubbles with the paintbrush and your index finger NOTE Now that the hole has been filled with a mixture of catalyzed resin and milled fibers the fiber glass mat has been applied over the interior and exterior of the hole the area has been restored to its original structural soundness IMPORTANT Because the repaired are
27. SAFE WORKING LOAD of the block then the next size larger ease remember that if a line turns back on itself like all ker sheets guys and jib top sheets then the load on that DOUBLED Spinnaker Gear o larger Genoas the spinnakers also get larger and need larger r to handle them As with the Genoa Gear our Spinnaker Gear t th loads that this beautiful sail can produce While not included in the the optional Reaching Strut is a necessity on boats over 30 xtrem in 25 kno jibs or Genoas Genoa and is identified by the amount of this overlap from the face of line 15 feet distant EW on tha to realize is that with a CLI very small area example pounds per square foot Since the above ALL of the Genoa The track are of the bes loads failures occur f fitting instead come close to th MUST HE USED Pl halyards spinna block is almost 5 17 4 With the trend t and stronger gea has been designed and fabricated to m but sometimes frustrating Spinnaker Gear and could SECTION 5 Page 36 5 17 4 Spinnaker Gear continued well be used on smaller ones In beam reaching conditions when the pole is up against the headstay an unnatural load is put on the mast stay and pole The reaching strut allows for a better angle of pull for the after guy pulling the pole off the headstay and thus reducing the loads to a safer poin
28. The genoa track is bolted through the track toe rail deck and hull A filler strip of 1 4 x 3 4 teak is furnished with some boats to install under the track on top of the toe rail In some boats this filler strip is molded Scribe a line on top of the teak toe rail the full length of the genoa track Place the outboard edge of the filler strip along this line and fasten the strip down with 3 4 brass escutcheon pins Use only enough to keep the strip fastened in a fair line to the top of the rail Starting from the stern locate the genoa track bolt holes on the center of the filler strip Then drill and bolt the track on working forward Install the track stops on the forward end of the track only Use ample sealant around each machine bolt Use the back up strip provided under the deck The main sheet track is bolted through the deck in the same manner as the genoa track using a filler strip Locate the SECTION 5 Page 4 5412 continued track according to the Deck Assembly drawing Make sure the cars will slide the full length of all tracks To mount dead lites drill a 1 4 hole from the bottom of the deck up through in the proper location From the top of the deck place the dead light so that the drilled hole is in the center of it Scribe a line around the body of the dead light on deck and cut around the scribe line with a saber saw or a hole saw Put a bead of sealant around the dead light underneath at t
29. The remote tank and the stove shall be connected by a continuous length with no splices or joints of Aeroquip Hose No 2651 5 protected with Aeroquip Fire Sleeve No 624 12 The hose assembly shall be assembled in accordance with the following diagram using the fittings indicated HOSE CLAMP Ne 8 5 5 AEROQOU P HOSE AEROQU P P N 2651 5 FIN 401 58 AEROQU P FIRESLEEVE AN 624 2 SECTION 5 Page 9 continued No substitutions whatsoever shall be made without checking with Sailcrafter Engineering After the assembly of the stove and tank are completed the following tests should be preformed a Fasten a quick disconnect fitting to the LPG fitting so that a hand air pump can be connected to apply pressure to the system b Close all valves on the stove and pump air pressure up to 10 psi and observe the pressure gauge for possible tank leaks e If no tank leaks are observed in test a above the tank stove system shall be left with this pressure applied for a minimum period of five hours For final inspection the following test should be made a Air pressure shall be applied to 10 psi with the tank valve open and all stove valves closed b If there is no measurable drop in pressure in a one hour period the system shall be considered acceptable If at any time during any of the tests described in this procedure a leak is detected the source of the leak shall be found and corr
30. a cannot be seen from inside the structure it does not have to be sprayed with gel coat H Repairing Hole That Can Be Seen Inside the Structure 4 Sand outward at least 2 inches on all sides of the hole with the power sander and 24 grit sanding disc so that additional fiber glass materials can be applied Cup out the sanded area smoothly so that a smooth even buildup can be achieved SECTION 6 Page 30 3 57 continued 2 Clean the area thoroughly with a white cloth saturated with acetone 3 Select the layers of patching materials mat and woven roving or mat only according to the type of fiber glass visible on the inside of the structure see Section 6 3 Procedure C Step 2 9 Patch the area as instructed in Section 6 3 Procedures D through G 5s Complete the repair by finishing the surface as instructed in Section 6 3 Procedure H IMPORTANT spray finishing the surface is necessary when the repaired area can be seen from inside the structure such as a boat or shower stall SECTION 6 Page 31 6 4 FINISHING TECHNIQUES NOTE It is recommended that small areas be finished with gel coat because the color and texture of the surrounding surface should be matched For new surfaces it is best to obtain the gel coat in the original color from the manufacturer of the part being repaired If for any reason matching gel coat is not available obtain a gel coat that matches the surr
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32. all thru hulls at the same time is a good idea It is extremely important for the safety of your yacht that all thru hull glass work be done very carefully in accordance with Section 5 5 Once the interior is complete the next step should be to install all deck hardware and deck wood in accordance with the drawings Be sure that all hardware and wood is carefully through bolted and very carefully sealed when installed to eliminate any possibility of leaks After your deck is complete it is suggested that you do whatever touch up work is required on the hull fair in the keel using micro balloon filled resin and install the rudder in accordance with the drawings and Section 5 7 After this work is complete the Tri Lux T B T O step is to clean buff and polish all fiberglass surfaces and apply an anti fouling coat to the bottom in accordance with Section 3 6 If you bought a spar kit the next step is to complete the mast and boom in accordance with Section 5 18 After this is complete you are ready for the long awaited day of launching Buy a couple of cases of champagne one bottle for your boat the rest for you and your friends and launch your boat in accordance with Section 5 19 SECTION 5 Page 5 HULL TO DECK JOINTS 08 Hull to Deck Joint with H Metal Sand outer and inner gel face off 1 2 from the edge the full length of the hull and deck and across the transom Prior to joining the hull and
33. ame applies to the dinette seats The sets or drawers and doors are set into the cutouts and are drilled countersunk screwed and plugged SECTION 6 Page 1 Rigging 5 416 Spars and If you have purchased the Sailcrafter spar and rigging kits you the drawings carefully assemble the mast as Be sure that track are separated from This helps Dip each in the future your yacht tape should following the final step in the construction of all stainless steel parts such as sail rs using a vinyl electrical reduce the possibility of electrolysis the aluminum spa Screw as you screw it into the mast in a quality grease which All winches should be mounted on appropriately shaped teak blocks to both give proper If winches are t should also be separated the possibility of pins in the all reducing electrolysis rate them from the aluminum mast re placed in re that cotter pins a all rigging pins Tape should be applied over to avoid sail damage Prior installed d be t surface of a mast 1 by a non metallic material to reduce r the mast is rigged rigging shoul to leaving for launching all running also assists in support and sepa mounted on a fla corrosion Be su mast head and in these areas afte on the mast SECTION 5 Page 32 5 17 Launching amp Commissioning Now tha
34. aned thoroughly cracks and flaws are repaired anda release agent such as a wax is applied The proper gel coat is then brushed or sprayed onto those mold surfaces corresponding to the external surfaces of the finished part After the gel coat has cured enough glass fiber laminates for the desired thickness of the product axe cut to fit the mold and the resin is prepared with catalysts and or promoters Glass and resin are then added alternately until the laminate is complete Each layer of glass and resin is worked with serrated or grooved rollers or squeegees to facilitate the resin s wetting of the glass to remove air bubbles and to obtain the desired thickness The finished laminate is allowed to gel undisturbed and then as soon as practicable it is extracted from the mold and set aside to complete its cure before subsequent finishing operations begin In Sprayup a mechanized improvement on hand layup resin and chopped fiber glass roving are sprayed simultaneously onto the mold surface The resulting mass is then rolled and cured SECTION 6 Page 6 6 2 BASIC PROCEDURES FOR REPAIRING SURFACE DAMAGE 612 1 Introduction The purpose of this chapter is to give you the basic procedures for making surface repairs to gel coated fiber glass products or parts IMPORTANT To determine how to repair a particular type of surface damage refer first to the appropriate section Surfa
35. anufacturer s instructions With a putty knife apply the catalyzed mixture around the corners where the backup patch comes in contact with the hole to seal off any sections of the hole that have not come into complete contact with the backup patch Allow the mixture to cure when the mixture has cured feather or roughen up the area lightly with the power sander and 29 grit sanding disc Be sure to cup out the sanded area smoothly so that a smooth even buildup can be achieved 11 I2 13 14 NOTE SECTION 6 Page 7 continued Patching the Remaining Area Continue the repair by building up the remaining area of the hole with pieces of fiber glass mat as instructed in Section 6 3 Procedures D through G Finishing the Surface Complete the repair by finishing the surface of the patched area as instructed in Section 6 3 Procedure H Repairing Holes Over 1 4 Inch in Diameter TOOLS MATERIALS Power sander Fiber glass mat 24 grit sanding disc Fiber glass cloth Sanding block Resin Rubber squeegee Catalyst Putty knife Sandpaper 50 amp 100 grit Scissors Cardboard Stirring stick Acetone Paintbrush Woven roving White cloth Masking tape Cellophane Milled fibers Sanding the Hole R With the heavy duty sander and 24 grit sanding disc sand all sides of the hole outward at least 2 inches Zi Cup out the sanded area smoothly so that at least two layers of fiber glass mat can b
36. apped air Build up the damaged area about 1 9 above the surface Bhs Immediately after you have applied the putty place a piece of cellophane over the patch to start the cure The cellophane should overlap the patched area about 1 inch on all sides With a single edge razor blade squeeg over the cellophane to remov xcess putty and air bubbles Hold the razor blade at as low an angle as possible that is almost flat in relation to the surface This technique leaves enough excess gel coat in the patch to allow for shrinkage and removes most of the remaining excess gel coat from the area If you do not allow shrinkage the gel coat will be below the surface when it cures and you will have to apply additional putty SS With the razor blade and before the gel coat cures scrape off the excess gel coat that you removed from the patched area in Step 4 above 6 Allow the putty to become firm and hard to the touch Then remove the cellophane D Sanding the Patch la Block sand the patch with 220 grit sandpaper to remove the excess putty and to restore the area to its original shape Zee If tiny pin holes appear in the patched area after you have removed th xcess putty apply additional putty as instructed in Steps A through C below If there are no pin holes go on to Step 3 IMPORTANT Confine the sanding operation as close as possible to the patch Pay very close attention to the area at all times In that way you can re
37. ard on all sides from the fracture or puncture at least 2 This technique allows the subsequent fiber glass patch to bond to structurally sound material Also be sure to cup out the sanded area smoothly so as to achieve a smooth even buildup SECTION 6 Page 7 6 3 1 continued 2g Clean the area with a white cloth saturated in acetone Ciz Cutting the Fiber Glass Patch T Cut pieces of fiber glass mat to build up the sanded area Cut the first piece to the size of the lowest point of the sanded area and continue outward with other pieces for an adequate buildup The last piece of mat should overlap the others about 1 4 inch 2 Build up the sanded area about 1 8 inch above the top to allow for shrinkage of the resin Press the pieces of dry fiber glass mat firmly in the area with your hands to insure a sufficient buildup If there are any low spots add more pieces of mat IMPORTANT Fiber glass mat will not maintain its thickness when wet out with resin That is why it is so important to press the pieces of dry mat firmly into the area with your hands to insure a sufficient build up Cut a piece of fiber glass cloth that completely overlaps the built up patch about one inch Bs D Wetting Out the Patch Mix resin and catalyst thoroughly with a stirring Stick to prevent uncured spots Follow the resin manufacturer s directions for proportions One at a time place each piece of fiber glass mat on a pie
38. be left with this pressure applied for a minimum period of five 5 hours Ce During the final inspection the following tests shall be made of the stove tank system SECTION 5 Page 1 5 10 2 continued 1 Air pressure shall be applied to 10 psi with the tank valve open and all stove valves closed 2s If there is no measurable drop in pressure in a one hour period the system shall be considered acceptabl 6 If at any time during any of the tests described a leak is detected the source of the leak shall be found and corrected and the test shall be started over again Installation of Windows Cut out along scribe line for proper fit o or make a template It is best to make a 1 plywood template of th inside of the window with the securing ring removed Tape these to the cabin with masking tape and the aligns checked for symmetry and the overall aesthetic When all the templates are taped in place sc around them Remove the templates and make th outs along the scribe lines Place bond between liner and deck to insure sole fit using 3 oz of mat and clamp until resin c Sand gelcoat off inside and outside for 1 2 all way around the hole Use a polyurethane sealant liberally under the frame and to the inside of the window frame Install wine Tighten screws until a small amount of the sealant squeezes out around the frame Window is complete 44 SECTION 5 Page 3
39. ber glass patching material can be applied Following the general instructions of Section 6 3 Procedure C sand outward about 2 inches on all sides from the patch that you have applied from the outside of the structure Complete both Steps 1 and 2 of Procedure C in Section 6 3 3 Patch the hole as instructed in Section 6 3 Procedures D through G IMPORTANT Select the layers of patching materials according to the type of fiber glass visible on the inside of the structure see Section 6 3 9 Procedure C Step 00 SECTION 6 Page 4 3 5 22 continued De Finishing the Outside and Inside Surf Ts Clean the outside and the inside patched areas thoroughly with a white cloth saturated with acetone 2 Apply gel coat putty to the outside of the inside patched areas as instructed in Section 6 3 Procedure H 35 Spray finish the outside of the inside repaired areas with matching gel coat as instructed in Section 6 4 6 3 6 Repairing Punctures From Outside the Structure Only TOOLS MATERIALS Power sander Fiber glass mat 24 grit sanding disc Fiber glass cloth sanding block Resin Rubber Squeegee Catalyst Putty knife Sandpaper 50 amp 100 grit Scissors Gel coat Stirring stick Cab o sil white cloth Acetone Wire Milled fibers Stick Cellophane B Removing Damaged Fiber Glass 1 Remove the damaged fiber glass from the area as instructed in Section 6 3 Procedure C NOTE If the hole i
40. ce of cardboard and apply the catalyzed resin wet out with a paint brush Saturate the pieces of mat thoroughly and work out air bubbles with the paint brush before applying the pieces to the sanded area Using the cardboard prevents resin from draining into the sanded area being repaired SECTION 6 Page 18 6 3 1 continued E Applying The Patch 1 As you apply each piece of wetted mat to the sanded area work out the air bubbles with the paintbrush and your index finger IMPORTANT If air bubbles are not removed they will leave deep voids in the patch after sanding so that you might have to apply additional fiber glass mat 25 Place the piece of dry fiber glass cloth over the patch immediately after the last piece of mat has been applied 34 Apply a rubber squeeg over the cloth Hold the squeegee at a 95 degree angle and apply it from one end of the cloth to the other Let the undamaged area surrounding the patch serve as a guide for contouring the patch properly NOTE Besides restoring the approximate original shape to the area the squeeg removes the remaining air bubbles in the patch Also the cloth makes squeegeeing possible It is impossible to squeegee directly on wetted mat IMPORTANT Tak xtreme care to remove as little of the resin as possible from the patch If too much resin is removed with the squeeg the patch will be resin poor that is not enough resin will remain in the patch t
41. ce repairs to fiber glass products or parts consist of restoring the gloss removing scratches and repairing air bubbles nicks and small holes gelcoat crazing and gel coat wrinkling The basic procedures described in this section generally apply to all of the above repairs except restoring the gloss A Tools and Materials Needed Tools and materials needed for repairing all six types of surface damage covered in this manual are given below TOOLS Heavy duty polisher Harsh grit buffing compound Huffing pad for polisher Acetone White cloth Water Sanding block Gelcoat Putty knife Cab o sil collodial silica Cellophane Catalyst Single edge razor blade Milled fibers Rubber squeegee Sandpaper 100 220 400 600 grit H Preparing the Surface Fox restoring gloss or removing scratches the surface is first cleaned with acetone For repairing other types of damage the damaged material is first removed with sandpaper or a putty knife and then the void is cleaned with acetone BE SURE TO READ THE APPROPRIATE CHAPTER FIRST Gs Patching the Surface X Make a smooth thick manageable putty with the ingredients given in the appropriate section 6 9 for the type of surface damage you are repairing NOpatch is required for restoring gloss or removing scratches SECTION 6 Page 7 6 2 1 continued 2 Apply the putty firmly in the void with a putty knife to force out all the tr
42. cetone leaving the surface free from grease and other contaminates Mix a fairly thick batch of micro balloons to a consistency that is easily workable with a putty knife and lay up into the recess of the joint about six feet at a time Make this a cool mixture so you will have from 30 45 minutes to work with it Next take the mahogany strips that are provided cut into lengths and force up into the micro balloons until the bottom of the strips are just above the bottom of the joint In most areas you can cut some cleat stock 1 x 1 pine and using the shelf space or cabinet tops of the hull liner as an anchor base force the mahogany strips in tight Before the micro balloons go off scrape all the excess from the joint with a putty knife Continue this process completely around the hull With micro balloons fill in all areas so you have a flush joint from the deck to the hull When the micro balloons have cured apply a strip bond across the joint extending 3 upward on the deck and down the side of the hull The bonds should consist of one layer of 3 oz mat and one layer of bonds a continuous strip Cut the pieces 3 or 4 feet long and overlap the ends 2 3 inches The mat comes in 5 widths and the cloth in 6 widths This allows 7 1 2 oz cloth It is not necessary to make the the cloth to overlap the mat 1 2 and makes it a neat professional looking bond Use body putty to fill any small imperfections The joint is no
43. ch Ca R C MARINE 17422 Armstrong Santa Ana Calif GEM MARINE Lake City South Carolina WILCOX CRITTENDEN Middletown ass SCREWS STAINLESS STEEL SINKS STAINLESS STEEL STOVES ALCOHOL amp BUTANE TANKS FUEL THRU HULL FITTINGS BRASS SECTION 2 Page 10 VIP RUBBER 945 So East Street Anaheim Calif Wefco Rubber Products 1655 Euclid Santa Monica Ca Lu AMERICAN APPLIANC 2425 Michigan Santa Monica Ca GALLEY MAID Riviera Beach Fla Local marine hardware PETERS amp RUSSELL Springfield Ohio Local marine hardware ELTZ BROS TU orfolk Va Industrial supply house Oklahoma supply supply DEL CITY WIRE CO P O B 82457 Oklahoma City STANDARD WIRE amp CABLE 3440 Overland Los Angeles Calif Local automotive Local electrical RUB RAIL RUBBER ER HEATERS ER PRESSURE PUMP DOW GASKET vinyl foam tape WAT WAT WIN black 3 16 thick x 5 8 wide in 30 rolls 3M amp Bear 6 E PRIMARY WIR SECTION 3 Page 1 4 ECHNIQUES 3 1 Gel Coat Touch up and Repair Minor abrasions and scratches can be removed from gel coat with an abrasive automobile polish followed by a wax polish such as Johnsons J Wax Kit More serious damage and flashing areas sho
44. coat Clean out cup and gun with acetone at least once an hour Mask off surfaces outside the work area to prevent accidental overspray SECTION 3 Page 2 332 Micro Balloon Filled Resin Micro Balloons mixed with a polyester resin will yield micro balloon filled resin which is used in yacht construction for casting fairing and sealing Its pot life is longer and therefore cures more slowly than pure resin The slower curing time allows more working pot life time and generates less heat without distortion Mixing Procedure 14 To prepare the micro balloon filled resin use no less than 1 2 and no more than to of catalyst by volume For example 1 2 ounce of catalyst with each gallon of clear resin 25s Add micro balloons to the catalyzed resin slowly stirring thoroughly 3 The mixture may be thick or thin and cure slowly or quickly depending on its application For example in large areas such as the keel rudder hull and deck fast curing is not required and Slow curing will avoid distortion 4 The mixture should appear and be about the consistency of a thin pancake batter Other areas where micro balloon filled resin is employed should contain more catalyst and more asbestos to form a thicker compound 35 Bonding All of the interior liners head liners and rubber tubes are fastened and secured to the hull and deck by bonding The bonding process is similar to bonding any type of stru
45. coat For the proper finishing procedures s Section 6 4 6 2 4 Repairing Air Bubbles TOOLS MATERIALS White cloth 2 Acetone Sanding block Water Putty knife Gel coat Cellophane Cab o sil Single edge razor blade Catalyst Sandpaper 220 900 600 grit SECTION 6 Page 1 6 2 4 continued B Preparing the Surface 1 Remove all the damaged gel coat surrounding the air bubble or air void with a putty knife The damaged gel coat chips off easily when you apply pressure to the putty knife Don t stop chipping until you have worked your way back on all sides to gel coat that is undamaged sound or firm 25 Clean the resulting void thoroughly with a white cloth saturated with acetone If the void is not cleaned properly a black ring will appear around the area after it has been patched Ce Preparing the Patch 1 Make a smooth thick manageable putty by mixing Cab o sil anda matching gel coat Mix thoroughly until all lumps have been removed IMPORTANT If all lumps are not removed from the putty they will trap air that in turn will leave tiny pin holes in the area being patched The lumps also will appear as white spots in the patched area 2 Add catalyst to the putty in accordance with the manufacturer s instructions Mix thoroughly so that no uncured spots will occur in the patched area on the unit D Patching the Void See Section 6 2 Procedure D Steps 2 thru 6 E Sanding the
46. cture rudder bulkhead etc However some items require thicker bonds for greater strength The procedures for making a bond are listed below a Bonding surfaces should be sanded clean of all paint loose glass fibers and any foreign matter which will interfere with a glass to glass bond SECTION 3 Page 3 343 Continued b All gel coat should be sanded off Sanding should be done with coarse paper min 40 grit 5 Bonding strips should extend a minimum of 4 on either side of the bond This means that if there is a space or a filler between the two surfaces glass strips wider than 10 will be required e Bond laminates should consist of the following on all boats l4 4 ozs mat under 24 oz woven roving 10 wide covered by 7 1 2 oz cloth 12 wide on all bulkheads around the forward water tank at the aft end of the hull liner where bunks and shelves contact the hui 2 All other bonds should consist of 3 oz mat plus one layer of 7 1 2 oz cloth f No more than 2 catalyst by volume should be used in the resin mixture Excellent material used in boat construction that will bond well are marine plywood exterior plywood most hardwoods and hardened plywoods Solid teak is an exception as it is a very oily wood which is incompatible with the resin To bond teak plywood the teak outer surface must be removed to the fir core for 4 from the edge Should you deci
47. d be lubricated with a heavy silicon grease before installation in order to shut out the water which is necessary for electrolytic action Fasteners for all component kits can be acquired from Sailcrafter Yachts at any time These fasteners are factory approved and are all individually sealed in plastic containers for your convenience SECTION 2 Page 4 2 6 Supplier Vendors List INTRODUCTION The following Suppliers Vendors Bill of Material list is given as a suggestion to help you complete your Sailcrafter Kit boat Although not all the pieces and parts have been listed the major components for completion are included BEDDING COMPOUND DOLPHINITE DOLPHIN PAINT amp CHEMICAL 922 Locust Street Toledo Ohio Local marine hardware BEDDING COMPOUND PRC 80AT LIF 152 65 Bloomingdale Rd Hicksville N Y Local marine hardware BILGE PUMPS PETERS amp RUSSEL Springfield Ohio Balboa Marine Hardware Newport Beach Ca BODY PUTTY POLYESTER Automotive amp paint stores Body shop BOTTOM PAINT INTERNATIONAL SAINT CO 21 West Street New York N Y WOOLSEY BRAND PAINT STORE BALBOA MARIN 1 Newport Beach Calif CUSHIONS JOHANSEN amp CHRISTENSEN 898 W 16th Costa Mesa Calif MARSHALL amp SONS 14903 Lakewood Paramount Ca Columbia Yachts Portsmouth f excess stock SC 23 60 27 SC28 50 6
48. de to lay out your own interior and not use the hull liner or modify the hull liner you will have to bond all bulkheads cabinets and floor boards to the hull 3 4 Cutting Drilling and Grinding Polyester resin fiberglass is a quite hard and very durable material for the construction of sailboats When grinding SECTION 3 Page 4 3 4 continued cutting and drilling work is done on the hull or deck take care to watch your tools for dulling Drills and taps for example dull quickly and should be sharpened or replaced when inspection shows wear National Coarse Threads are generally preferred to National Fine Threads i e 10 24 NOT 10 32 Saw cuts can be made with special sabre saw blades see Suppliers and Vendors List or with an abrasive wheel on a high speed drill motor Any rough or uneven surfaces may be ground or sanded with a disk belt or orbital sander Avoid breathing the dust as it is an irritant to the respiratory system It is suggested that a mask be worn over the mouth and nose so as not to inhale powdered fiberglass Likewise power tools should be blown free of fiberglass dust since it is an abrasive in bearings motors and gears NOTE Caution should be used at all times when working with power tools on fiberglass The fiberglass is a very hard material and tools have a habit of slipping sliding and jumping out of place O5 Winterization For all boats with inboard engines and head
49. e The outside surface of a fiber glass structure is usually formed by a colored gel coat This is a special resin material containing concentrated color It produces a smooth finished surface that will give many years of service when these simple maintenance steps are followed
50. e 1 Ssl GENERAL ASSEMBLY INSTRUCTIONS After studying Sections 1 2 3 and the drawings included in Section 4 in great detail you are now ready to commence the work of building your Sailcrafter Yacht We suggest certain preparations and tools prior to starting work see 5 1 1 through 5 1 5 The rest of Section 5 covers the individual detailed instructions for your guidance If you are going to build your own wood interior instead of using the unitized fiberglass interior which is available it is important to plan the interior in as much detail as possible and to try to visualize the finished result before a single piece of plywood has been cut Work inside the boat marking the positions of all bulkheads on the fiberglass shell with masking tape chalk etc Make mock ups from small sticks and cheap plywood or cardboard just to help to visualize the finished result Then sit down and look at it try to sit at the dinette or on the bunks try to work at the galley try to operate the head Then change things around and try the above all over again until you are sure the interior suits your needs When this is done plan all assembly methods necessary for assembling the interior For example the main structural bulkhead to the mast post or the formica galley top joint to the galley face should be designed to conceal unfinished edges Be sure you have it all planned so that no unpleasant surprises will occur later
51. e applied later Applying the Backup Patch From outside the structure being repaired fasten a piece of cardboard and cellophane over the hole as instructed in 6 3 5 Procedure H Steps 2 through 5 The cardboard serves as a backing against which the milled fiber putty can be applied from outside the structure Step 2 below Cx NOTE SECTION 6 Page 8 1 continued 2 Make a putty of equal amounts of resin and milled fibers Mix thoroughly and then add catalyst in accordance with the manufacturer s instructions 3 Prom outside the structure apply the catalyzed putty in the hole with a putty knife Build up the hole smoothly and evenly 4 Allow the putty to cure 55 After the putty has cured remov xcess putty with the power sander and 29 grit sanding disc Cup out the sanded area smoothly so that a smooth even buildup can be achieved 6 Clean the area thoroughly with a white cloth saturated with acetone Patching the Outside of the Structure Continue the repair from outside the structure by building up the remaining area of the hole with pieces of fiber glass mat as instructed in Section 6 3 Procedures D through G Finishing the Outside Surface Complete the repair from the outside by finishing the surface as instructed in Section 6 3 Procedure H Patching the Inside of the Structure 4 Inside the structure remove the cardboard that you fastened over the hole in
52. e area with matching gel coat For the proper finishing procedures s Section 6 4 Repairing Simple Non penetrating Fractures TOOLS MATERIALS Power sander Fiber glass mat 29 grit sanding disc Fiber glass cloth Sanding block Resin Rubber squeegee Catalyst Putty knife Sandpaper 50 amp 100 grit Scissors Gel coat Stirring stick Cab o sil Paintbrush Cardboard White cloth Acetone Cellophane 235 sgg SECTION 6 Page 0 ER continued B Repair Procedure A simple fiber glass fracture is one that does not go all the way through the structure being repaired To repair this type of fracture see Section 6 3 Procedures C through H 623 3 Repairing Compound Fractures From Outside And Inside The Structure TOOLS MATERIALS Power Sander Fiber glass mat 29 grit sanding disc Fiber glass cloth Sanding block Resin Rubber Squeegee Catalyst Putty Knife Sandpaper 50 100 grit Scissors Gel coat Stirring stick Cab o sil Paintbrush Cardboard White cloth Acetone Cellophane Woven roving 8 Repairing Outside of Structure when a compound fiber glass fracture is accessible from both outside and inside the structure begin on the inside Repair the fracture as instructed in Section 6 3 Procedures C through G IMPORTANT Omit Step 3 cleaning patch with acetone of Procedure G in Section 6 3 for now Also when removing damaged fiber glass with the power sander Section 6 3 Procedure C Step 1 do not sand all th
53. e is bonded to the hull with three 3 layers of 3 oz mat and three 3 layers of 24 oz woven roving Catalyst content of resin not to exceed 2 by weight Apply in three applications of one layer of mat and one layer of woven roving This laminate must extend at least 5 out from tube and 5 up onto tube 4 The top of the tube should terminate approximately 2 from the underside of the cockpit sole or deck except when wheel steering is used In this instance there should be approximately 3 between the top of the quadrant and the underside of the cockpit sole SECTION 5 Page 3 continued 7 Lubricate rudder shaft and place Nylatron washer between hull and rudder Push rudder up Secure deck flange and place Nylatron washer under tiller head Install hex head set screw lining up rudder and tiller Drill through tiller head and rudder shaft and install hex head bolt and secure SECTION 5 Page 4 Keeling Procedure The entire keel must be painted with International Intergard No 4424 4423 Primer except the top and sides of the flange which must be sanded to white metal and cleaned with acetone The keel must be dry fitted with keel pocket to assure proper fit If the keel fits move to Step 3 If not a Mark areas that do not fit bs Remove keel and grind metal off Never grind fiberglass pocket Cu Refit keel to pocket to assure fit To determine that the keel is vertical
54. e way through the structure Cs Repairing Inside of Structure Ls On the inside of the structure remove the remaining damaged fiber glass as instructed in Section 6 3 Procedure C and until you can see the patch that you have applied on the outside of the structure SECTION 6 Page 1 3 continued Ze If the fiberglass design on the inside of the structure resembles a heavy woven material build up the sanded area with alternating pieces of fiber glass mat and woven roving instead of just mat as instructed in Section 6 3 Procedures D through F If the design resembles a light woven material use alternating pieces of fiber glass mat and cloth In either case apply a piece of mat as the first layer in the sanded area and then continue alternating the cloth with the mat E The final piece of fiber glass cloth applied is the one that overlaps the built up patch about 1 inch on all sides Section 6 3 Procedure D Step 3 Su Continue the repair as instructed in Section 6 3 Procedure G Steps 1 and 2 sanding the patch Finishing the Outside and Inside Surfaces 1 Clean the outside and inside patched areas thoroughly with a white cloth saturated with acetone 2 Apply gel coat putty to the outside and the inside patched areas as instructed in Section 6 3 Procedure N 3 Spray finish the outside and inside repaired area with matching gel coat as instructed in Section 6 9 4 Repairing Compound
55. ealant NOTE If a vent line or over flow line is not required by the plumbing drawing a 1 8 diameter hole will be drilled in the fill cap The fill shall be so located in the tank lid that it will be most easily accessible for filling when a cushion or carpet is in place over the tank 5 The lid shall be dry fitted to the tank top and drilled for mounting Screws There shall be a mounting screw in each corner The spacing between screw centers shall be 4 maximum 65 The inside of the tank shall be thoroughly cleaned prior to installing the top Bed the top in a liberal bead of silicone sealant The screws shall be oval head selftapping and finish washers shall be used for all berthtop installations Cabin sole installations shall use pan head self tapping screws covered with plugs The screws must be sealed SECTION 5 Page 7 5 9 continued Ta Excessive sealant should be displaced as the lid is secured This sealant shall be wiped to form a neatly appearing bead The screw heads shall be wiped clean See the drawing provided for the correct hot water connections to your engine from the hot water heater The head plumbing consists of the head discharge loop hose and thru hulls connected in accordance with the plumbing diagram All marine heads are shipped with the fittings loose Tighten all fittings on head Following the plumbing diagram place the pick up hose to intake on head and secure with stainl
56. ected and the test shall be started over again INSTALLATION OF ALCOHOL STOVES Alcohol stoves and their remote supply tanks shall be installed and connected in the following manner The stove must be securely mounted on its gimbals in such a manner that it can swing freely 30 from vertical Stainless steel cotter pins must be installed to retain the stove in the gimbals 5 101 5 10 2 SECTION 5 Page 0 5 10 22 continued 24 The remote supply tank must be bolted with stainless steel bolts and washers to the appropriate support It must be equipped with a cut off valve 3 The remote tank and stove shall be connected by a continuous length with no splices or joints of Aeroquip Hose No 2651 5 protected with Aeroquip Fire Sleeve No 624 12 The hose assembly shall be assembled in accordance with the following diagram using fittings indicated 4 No substitutions whatsoever should be made 5 After the assembly of the stove and tank are completed perform the following tests a Close the valve on the tank Pump air pressure to 10 psi and observe the pressure gauge for possible tank leaks bz If no leaks are observed in test a above then with all valves on the stove closed the valve on the tank shall be opened and the pressure drop noted after five 5 minutes This small approximately one lb pressure drop is caused by air Filling the system and is expected Th tank stove system shall
57. ed very carefully This is done by fastening clear plastic hoses to the hull one on the port side taped to the hull above the waterline and running under the boat to the starboard side again taped to the hull above the waterline The second tube should be fastened at the bow above the waterline and run aft to the stern and taped to the hull above the waterline These hoses should be filled with a vegetable dye colored water Then level the boat so that the water level is exactly the same dimension fore and aft and port and starboard above the waterlin After the hull is perfectly level you can proceed with your next step Sela 3 Temporary Cover Over Work Area It is recommended that a temporary cover be built over the area in which you will be working The roof should be strong enough to protect your work area from snow and rain and if you are working in a colder climate it is suggested that inexpensive plastic sheeting be used to construct a windbreak all the way around the structure Be sure that the roof is high enough so you can stand up on deck Since you will be doing fiberglass work it is important that the average temperature to held reasonably constant so that your fiberglass were will turn out well Extremes of humidity or temperature will produce poor fiberglass work which will have o be don ver Be sure you have good ventilation while you are doing fiberglass work to protect your health Having a temporary enclosure f
58. ency Do not thin more than 50 percent otherwise the acetone will dull the finish 2 Adjust the air pressure to between 30 and 90 pounds 3 Add the exact amount of catalyst recommended by the gel coat manufacturer Mix thoroughly to avoid uneven cure 4 Test spray gun on a piece of cardboard and adjust pattern control and trigger to regulate pattern The two should be balanced The smaller area to be sprayed the more the pattern and trigger nozzles should be closed D Applying Gel Coat Position surface and or lights so that you can see the spray pattern as it forms on the surface Spray gel coat on the area Spray uniformly to avoid producing light and heavy areas Apply 10 to 15 mils of gel coat approximately 5 mils per pass to allow proper flow and thus minimize orange peel and to produce sufficient buildup for final sanding and buffing MOVE GUN SLOWLY OR GEL COAT WILL RICOCHET OFF THE SURFACE Spray a very light film of polyvinyl alcohol PVA over the gel coat immediately This film seals off the air and Speeds up the cure to a non tacky surface that can be sanded It also protects the finish from dust CAUTION SECTION 6 Page 33 6 4 continued 9 Remove the masking tape and as soon as the gel coat has cured block sand it with 400 grit sandpaper and water to remove orange peel and any lap lines that may have developed Hand sand if necessary to smooth stubborn a
59. engths in pounds for 1 x 19 stainless steel wire cable as supplied by the factory 10 300 9 32 4 700 3 16 1 200 37 32 12 500 6 6 300 7 32 2 100 1 8 17 500 37 8 8 200 1 4 3 300 5 32 SECTION 5 Page 34 continued unless otherwis y th lower insulator is 7 6 specified while th upper insulator is from the top swag up 7 Backstays 2 7 5 On insulated backstays located 18 down from the bottom swage eye Gear IES Genoa The trend in modern yacht design has been to smaller main sails and larger Usually any sail that overlaps the mast is considered a Thus J on the sail plan is 10 feet anda LP was drawn parallel to the headstay 1508 Genoa What is extremely important these large sails can concentrate very high loads over a if the distance the mast to the bow then any Genoa line would be a hence the gear must have a high safe working load For ts of wind or ON a Genoa is subjected to a pressure of about 4 TON for a 500 square foot Genoa P load could easily be transmitted to one spot at any given time Gear has been designed and prepared to accept those extreme is thru bolted and all blocks are oversize All other fittings possible design and strength FOR THE JOB INTENDED Most fitting rom improper usage usually by trying to use a light or cheap of the proper factory recommended on If loads are expected to
60. ess steel hose clamps Be sure to apply Pemetex to fitting before clamping Place exhaust hose to flash on head Run hoses to thru hull fittings Place head on base and bolt secure Fill head with water Close gate valve and pump head Open thru hull Drain water Find and stop leaks For stainless steel sinks seal under edge of sink Install sink and weight it down until sealant has cured Use sink bolts to secure sink to underside of glass Clean off excess sealer SECTION 5 Page 18 SO Stove and Tank Installation LOE INSTALLATION OF LPG STOVES LPG stoves and their remote supply tanks shall be installed and connected in the following manner No changes in materials or methods should be made before checking with Sailcrafter Engineering 41 LPG means liquified petroleum gas properly known as propane butane or some combination of the two LPG under moderate pressure will liquify Upon relief of the pressure it is readily converter into a gas Due to this unique condition it is extremely important that the LPG tank and stove installation be carefully done and tested 2 The stove must be securely mounted on its gimbals in such a manner that it can swing freely 300 from vertical Stainless steel cotter pins must be installed to retain the stove in the gimbals Ju Remote supply tank or tanks must be installed in the fiberglass self draining sealed box in accordance with drawing STD 08 20110 4
61. g a damaged area you must spray the patched area with the appropriate finishing coat For the proper finishing procedures s Section 6 4 2 5 Some types of surface repairs always require a finishing coat When these repairs have been made be sure to finish them in accordance with the procedures given in Section 6 4 6 2 2 Restoring Gloss NOTE Restoring the gloss to a fiber glass product takes very little time but enhances its appearance con SECTION 6 Page 9 continued siderably giving it an almost like new shine For maximum satisfaction after you have repaired a hole or fracture buff the entire unit not just the repaired area TOOLS MATERIALS Heavy duty polisher Harsh grit buffing compound Buffing pad Acetone White cloth Water 2 Cleaning the Surface T Saturate a cloth with acetone 2 Wipe the surface of the fiber glass unit with the saturated cloth to remove all loose debris If not removed debris can scratch the finish during buffing Ses Repeat Step 1 as necessary to remove all debris Huffing the Surface 1 Attach buffing pad to a heavy duty polisher and apply harsh grit buffing compound to the pad Er olding the polisher at a 95 degree angle buff the unit with just enough pressure to remove grease grit and grime CAUTION APPLY MINIMUM PRESSURE TO CORNERS AND EDGES SO AS NOT TO REMOVE THE GEL COATING 3 Hold
62. ght to the laminate The choice of a particular form of glass fiber is dictated both by the properties desired in the finished laminate and by the method of layup discussed in Chapter 2 Generally the continuous fiber forms woven roving and cloth offer the most strength for a given thickness of laminate Their advantage lies partly in their continuous fiber form and partly in their capacity to be well saturated and wetted with relatively small amounts of resin Thus higher glass contents with higher strength can be achieved SECTION 6 Page 5 6 1 6 continued Chopped fiber materials include mat and other chopped rovings Although roving is sold as continuous strand material it is usually chopped during use These materials offer non directional strengths and are applied behind gel coated surfaces to prevent the weave pattern of the cloth or woven roving from being transferred to the exterior surface Still chopped fibers do not provide as high a level of strength and stiffness as do the continuous fiber products Gis Ey Manufacture of Fiber Glass Products Fiber glass products are manufactured by combining the basic materials described in a suitable mold are hand lay up and sprayup Several techniques are used two of which In hand lay up fiber glass materials mat woven roving and or cloth and resin are placed manually in the mold Hut first the mold has to be prepared It is cle
63. he junction of the flange the body and the deck and bolt through the deck For boats with the mast going through the deck the mast step must be installed level Lay out the J measurement on the centerline on deck he fore and aft outside measurement of the mast and add this to the 1 4 hole at this point on deck and drop a plumb bob down to the he point in the bilge at the point of contact with the plumb bob he center of the mast step Center the mast step on this point and with the boat Measure half WO 000 a bilge Mark t This will be rotate it to either port or starboard to align it with the centerline Then fasten down with the rest of the lag screws Measure the distance from the center ep to the center of the panting rod hole in the mast step then measurement on deck and drill the hole on deck for the panting rod of the mast section from plywood and add 1 4 all around Lay of the mast s transfer this Make a templa this out on deck with the center of the template centered with the 1 e plumb Scribe around the template Then with a saber saw make the cut hole on deck out The 1 9 oversize will allow for wedges when you step the mast SECTION 5 Page 5 5 13 Exterior Wood If your boat has toe rail caps they are teak and are cut to the proper shape to fit the deck however there is some fitting and trimming left to be done Start at the transom and f
64. ide edge to the line as you did on the outside and finish the top edge off with the 1 4 bullnosed radius The main hatch consists of Cribboard Guides main hatch main hatch guides clips main hatch beam sill one set of louvered doors and drop down cribboards on some boats On others drop in cribboards are used in place of louvered doors Locate them in accordance with the Deck Assembly drawing The cockpit coaming blocks and coamings come pre fit and it is merely a matter of fastening them on with screws countersunk and plugged Start with the coaming blocks Then the coamings and then the helmsman s seat backrest This last mounts with the bottom flush with the bottom of the Side coamings and will keep the water from running into the cockpit The helmsman s seat is also pre fit It mounts up under the side coamings and the backrest in the hack Screw from under the seat into the coamings and backrest There are four knees provided to give the helmsman seat added support in the 5 50 only Two are spaced evenly off the centerline aft and one each port and starboard These are screwed onto the fiberglass side by first marking their location and then drilling holes from the cockpit into the lazarette area and screwing them from inside the lazarette out They are also screwed and glued at the top down through the helmsman seat and then plugged Winch handle boxes are located in accordance with the Deck Assembly drawing Take the mea
65. ing the polisher flat on the surface and applying very light pressure buff the unit to restore the gloss and remove slight scratches 4 To remove heavier scratches see Section 6 2 3 Removing Scratches TOOLS MATERIALS Heavy duty polisher Harsh grit buffing compound Huffing pad Acetone White cloth 2 Water 3 SECTION 6 Page 10 6 2 5 continued H Preparing the Surface d Saturate a white cloth with acetone 2 Wipe scratched area with the saturated cloth to remove all loose debris If not removed debris can cause additional scratches C Removing the Scratch 15 Block sand the scratch with 220 grit sandpaper until Scratch disappears Wipe the sanded area clean with a white cloth saturated with water This step is necessary to prevent large particles of dust from scratching the gel coat IMPORTANT Carefully observe the scratch while sanding it so that you can stop sanding immediately when the scratch has been removed If you are not careful you might sand all the way through the gel coat and thus have to replace it D Sanding Buffing and Spraying dx Wet sand the repaired area as instructed in Section 6 2 Procedure E Steps 4 and 5 2 Buff the repaired area as instructed in Section 6 2 Procedure F du If the gel coat has been sanded through during Procedure C above that is fiber glass is visible you must spray the area with a finishing
66. inish with teak plugs over dolphinite sealant wn ECTION 5 Page 28 5 14 Electrical System 12 Volt DC The lighting wiring harness is molded in the deck liner in most boats All connections should be with Stak on type connectors and terminal wiring eyes All wiring harnesses should be bundled and wrapped with plastic ties every 19 Care should be taken to route all cable bundles up out of the bilge so bilge water cannot get to them For connections to bilge pumps and other bilge mounted electrical devices the connection should be well up out of the bilge The mast wires come through the mast step and are secured to a female plug A male plug is wired in the same manner to the mast wiring so the mast can be disconnected easily when unstepped Secure wires to the Master Control Panel in accordance with the wiring diagram using ring type stak on terminals SECTION 5 Page 9 5 15 Cabinetry Interior Wood The interior cabinetry and wood parts should be located in accordance with the Interior Construction drawing The main bulkheads around the head should go in first These are all pre cut and should follow from forward to aft Set the bulkheads in the recesses provided Plumb them with a level and then fasten them into the hull liner by countersinking screwing and plugging A good waterproof glue should be used at all wood to wood joints and a sealant behind the wood in any area where there may be wate
67. it the transom cap down over the toe rail the rail caps are dadoed out on the bottom side Fit and fasten down temporarily by countersinking and drilling the screw holes The transom cap will extend slightly beyond both sides of the transom Cut these ends off on approximately a 450 angle with the side rails Place the side rail caps on the side rail and butt them up against the transom cap Make a line on the side rail cap parallel with the 450 cut on the transom cap then cut the side cap to fit Once you have made the preliminary fit butt the two pieces together and if they don t fit exactly flush a single saw cut at the joint will with both pieces butted together give you the desired joint Continue up both sides of the rail screwing the rail down as you go The side caps have a scarf joint at each end except the aft pieces against the transom These are easily fitted together and keep the rail caps from splitting lengthwise When you get to the bow cap it is fitted in the same way as the side rail caps Some trimming out at the underside maybe needed so ii will set down flush This can be accomplished by laying the bow cap it is in two pieces in line with the rail cap and scribing the underside Use a sharp chisel to remove the wood to the scribe line When the complete rail cap has been temporarily fastened down lay a thin batten along the outboard edge of the rail cap so that the edge of the batten just touches the outb
68. m 6 and inner hull laminate for an area around the thru hull large enough in diameter to allow the plywood donut to seat properly 3 With the thru hull temporarily located fill the void around it with random matting and resin Item 5 as shown 4 Bond over this filling with a cover bond Item 1 according to Section 5A of CSP 00 9031 1 lam 24 oz roving and 3 oz mat 5 Finish the installation by sealing the thru hull and tightening nut Item 3 6 If the thru hull device is of a flush mounting type use a bond equal to the outer hull laminate to secure it in place prior to filling the void as defined in Step 3 SECTION 5 Page 1 5 6 Chainplate Installation Drill hole in deck elongating to fit chainplate Place chainplate through deck and secure Seal around chainplate below and above deck Use Minnesota Manufacturing Company Weather Ban Sealant Tape 3 wide and 1 8 thick Slit and place over chainplate and secure chainplate cover Trim excess sealant with knife SECTION 5 Page 12 5x Rudder Assembly Drill hole in hull at rudder location for size see drawing Align the rudder tube drill hole in deck Bond rudder tube to hull as follows 1 The rudder tube is extended through a clearance hole in the hull and aligned with a locating jig 2 Tube is filleted to the inside of the hull with a small amount of asbestos filled resin as shown Catalyst should not exceed 1 2 to 1 by weight 35 The tub
69. mel and Spray Equipment 1 Follow the manufacturer s instructions printed on the package label If a two part enamel is used be sure to measure accurately and mix thoroughly 2 Follow manufacturer s instructions for thinning It is important that you do not over thin the enamel and that you use the specified thinner Sis If you are going to spray th namel test the spray pattern on a piece of cardboard and adjust pattern control and trigger to regulate pattern D Applying the Epoxy Enamel qs Position surface and or lights so that you can see the Spray pattern as it forms on the surface If you use a brush be sure it is a good properly prepared bristle Brush th namel on evenly 2 If multiple coats are specified by the enamel manufacturer allow proper drying time and sand lightly between coats 6 4 2 Protective Maintenance One of the major benefits of a fiber glass reinforced structure is the reduction of maintenance chores There are only thr relatively easy maintenance rules to follow to keep the surface looking like new SECTION 6 Page 5 6 4 2 continued Le Clean the exterior surface with detergent and a soft sponge and apply a good automotive type wax Do this about as often as you would clean and wax your car 2 3 Touch up and patch scratches scars and small breaks She Repair any major breaks as soon as possible to avoid additional damage to the structur
70. move the excess putty and contour the area properly without sanding through the gel coat to the fiber glass As a result you won t have to spray the area in order to restore the surface to its proper condition a Apply just enough putty to fill the pin holes In that way the area will require very little sanding SECTION 6 Page 8 62 continued 5 Cover the patch with cellophane to start the cure Remove th xcess putty with a single edge razor blade s Procedure D Steps 4 and 5 above om When the putty has cured remove the cellophane and block sand the patch with 220 grit sandpaper as instructed in Step 1 above 35 Remove all dust with a white cloth saturated with water 4 Wet sand the area with 900 grit sandpaper and water to remove the scratches resulting from the 220 grit sandpaper 52 Wet sand the area with 600 grit sandpaper and water to remove the scratches resulting from the 400 grit sandpaper E Buffing the Patch l Attach buffing pad to a heavy duty polisher and apply harsh grit buffing compound to the pad 2 Holding the polishes at a 95 degree angle buff the patched area with just enough pressure to remove remaining scratches sandpaper grit etc 3 Restore the gloss to the area by holding the polisher flat and applying only light pressure F Spraying the Patch T If you have sanded through the gel coat or other surface finish that is fiber glass is visible while patchin
71. n manufacturer s data sheet to determine the correct amount of catalyst and promoter if required for good results The time required far solidification to begin is commonly known as the gel time Even mildly over catalyzed resin cures in a hard solid rather sooner than desired so that the time available for the production of a finished part is reduced and quality may be lowered On the other hand undercatalyzed resin may cure very slowly if at all and attempts to use it will result in a prolonged waste of time and labor To lengthen the pot life of catalyzed polyester resin fiber glass workers recommend the following practices it Mix only small quantities of resin and catalyst at a time Avoid high ambient surrounding air 2 temperatures 3 Keep containers cool such as by placing them in ice water Here are some suggested safety precautions qs Allow ample ventilation 2 Keep away from open flames and sparks Ju If promoter is required add carefully controlled amounts to the resin first and then add the catalyst 4 Never mix just promoter and catalyst together a violent explosion will result 6 14 55 Gel Coats The glossy opaque and usually colored surface of a fiber glass product is called the gel coat Its purpose is to protect the product as well as make it attractive to th ye For example the gel coat covers up protruding surface SECTION 6 Page 4
72. nd rigidness to a fiberglass laminate Without woven roving a laminate of fiber glass cloth and mat would bend and flex Woven roving like mat is designated in approximate weight per square yard 24 oz woven roving for example NOTE A detailed explanation concerning the nature of fiber glass is covered in Section 6 on fiber glass repair 2 2 Resins and Catalysts The resin used to solidify the fiber glass in all Sailcrafter Yachts is a polyester resin Use only polyester resins when applying fiber glass to your Sailcrafter Yacht other types of resin will not be compatible SECTION 2 Page 2 2 2 continued Before the resin can be applied to fiber glass for a bond or lay up it has to be catalyzed The catalyst is an agent which works chemically to cure the resin into a solid state Once a batch of resin has been catalyzed the pot life or time remaining in which the resin can be worked effectively before it turns into a solid mass is very limited Catalyzation of resin should be at the rate of 1 2 to 4 per volume increasing with decreasing temperature For example on a hot day 75 800 you will want to catalyze your resin with only about 1 20 per volume On colder days 50 600 you will want to add more catalyst NOTE It is best to read the section on Resins in Section 6 befor xperimenting with resins 24 3 Gel Coat The glossy finished exterior color you see on a fibe
73. o combine with the fiber glass 4 Remove the piece of cloth immediately after the patch has been properly squeegeed Removing the cloth reduces the amount of sanding that has to be done later 3 Allow the patch to cure before going to Procedure G F Sanding the Patch i When the patch has cured remove the majority of the excess fiber glass and restore the original contour to the area with the power sander and 24 grit sanding disc SECTION 6 Page 9 continued Remove the remaining excess fiber glass and all ripples from 7 the patch by block sanding the area thoroughly with50 grit sandpaper Apply the sanding block in a continuous pattern across the patch so that ridges will not be left from the block 34 Clean the area thoroughly witha white cloth saturated with acetone Finishing the Surface ibe Mix Cab o sil with gel coat to form a thick creamy putty 2 Add catalyst to the gel coat putty in accordance with the manufacturer s instructions 3 Apply the catalyzed gel coat putty to a rubber squeegee 4 Apply the putty smoothly over the patch with the squeegee to fill all the tiny pin holes Hold the squeegee at a 45 degree angle and fill in any minor indentations in the fiber glass patch with the gel coat putty Allow the putty to cure 8 6 Remove th xcess putty and properly contour the area by block sanding with 100 grit sandpaper diss Spray finish th
74. oard edge of the cap Keep the batten in a fair line and scribe a pencil line on the top of the teak cap all the way around the deck Then with a belt sander sand down to the pencil line This will give you an even fair line on the outboard side of the rail cap Radius the top outboard edge with a hand router 1 9 radius to finish it off Leave the inboard edge of the cap unfinished for the present Remove all the rail cap and then use Dolphinite sealant along the edge of the fiberglass joint where the deck and hull flanges join Use another application in the dadoed out cavity of the rail cap Then fasten all rail cap to rail permanently using stainless steel self tapping screws and finishing off with teak plugs When it is all fastened permanently install nibbs inset knees at the inside how cap joint and the port and starboard joints where the side caps join the transom cap Lay the nibb on top of the cap so the center point of the nibb is on the center joint cut SECTION 5 Page 6 5 13 continued Scribe a pencil line around the nibb and chisel this out of the rail cap Insert the nibb and screw a countersink horizontally from the inside of he nibb to the rail cap Measure the cap from the outside edge until you ind the narrowest point Use this as the overall width dimension Lay out a line on the inboard side of the rail cap with a batten parallel to the outboard edge Sand down the ins
75. on or simply a cure Two ingredients ar Ssential to the successful polymerization of a polyester resin a catalyst and a promoter A catalyst is a material that by its presence aids a chemical reaction without actually taking part in the reaction itself In the classic case a catalyst could be removed from the products of a chemical reaction and used again and again Polyester resin development however has lead to the use of peroxide compounds as catalysts for the curing reaction Being somewhat unstable though these compounds tend to break dawn and thus yield other products that actually do the catalyzation The peroxide compounds also cannot be recovered afterward because the product of a polyester cure is a solid resin mass Nevertheless as the peroxides do not chemically enter the polyester reaction they are true catalysts A promoter is a material that enhances the action of a catalyst without actually having any catalytic value itself Most resin manufacturers supply resin either with or without a promoter mixed in Promoted or Unpromoted All the promoted forms have a reasonable long shelf life when stored as directed SECTION 6 Page 3 6 1 4 continued Ideally resin should be so catalyzed that it begins to solidify as soon as it has been combined with the desired reinforcement and formed into the desired shape Since the time required for these operations varies refer to the resi
76. on to Fiberglass urface Repairs I S Fracture and Puncture Repairs inishing Techniques E 1 14 xls 16 SE 00 Or C Ga G1 O O1 G1 O OY OF ECTION n ECTION I INTRODUCTION This Builders Instruction Manual has been prepared by experts with a great deal of knowledge and experience in the field of fiber glass boat building This knowledge and experience is represented in the pages you are about to read The manual has been broken down into six separate sections General Techniques Bill of Material Defined amp Explained Blueprints and Drawings Installation of Component Kits O01 WN Fiberglass Repair Section 5 covers the installation and assembly of your Sailcrafter Yacht You will be referring to this section continuously Sections 2 and 3 deal with the jargon processes and procedures used in the fiber glass sailboat construction These sections should be read first as they will help you to understand what is being said in the Installation Section Section 4 deals with blueprints drawings and data concerning the assembling of your Sailcrafter Yacht This section will be used in conjunction with Section 5 The language used in the Manual has been simplified fo
77. or your work station will make it more pleasant and enjoyable to build your Sailcrafter Yacht 5 1 4 Importance of Leveling The importance of checking all your work with an accurate carpenter s levelcannot be over emphasised Since your boat is level checking each of the parts you install with a level will your final product square and true with respect to the waterline of the boat If you have purchased your SECTION 5 Page 4 5 1 4 continued Sailcrafter Kit with the interior installed you will note that there is draft in all of the vertical surfaces This is necessary in order to remove the interior parts from its mold Vertical surfaces cannot be used as a reference for locating wood parts or else they will be tilted at the angle of draft rather than vertical with respect to the waterline of the boat This is another reason why the constant use of a level is extremely important When mounting bulkheads it will sometimes be necessary to shim them where they contact the fiberglass surfaces to insure that they are vertical 531 55 Order of Assembly It is suggested that you start work on the interior first Since the interior has a great deal of detail fiberglass wood and mechanical work getting this completed first makes a lot of sense Completing the engine installation in accordance with the drawings and Section 5 4 of this manual should be the first order of business Installing
78. ounding color as closely as possible and if necessary shade the gel coat with polyester paste colors to more closely match the surrounding color TOOLS MATERIALS Suction spray gun Gel coat White cloth Catalyst 100 400 6 600 grit wet Acetone 6 dry sandpaper Polyvinyl alcohol PVA Masking tape Buffing compound Sanding block Water Paper Stirring sticks Buffing pad heavy duty polisher B Preparing the Surface 1 Prepare the surface as instructed in Section 62 is After the area has been thoroughly sanded and feathered apply masking tape Where possible place the tape on a sharp break or contour adjacent to the area This technique minimizes slight color or texture differences after spraying NOTE Mask a large enough area so that you will not have to spray closer than 2 inches to the tape If you spray up to the tape a thick lap line that is difficult to remove will result S It is of extreme importance to sand and feather evenly to the tape after it has been applied If you don t the gel coat overspray will not bond and peel back or flaking will occur SECTION 6 Page 32 6 4 continued 4 Cover with paper any areas that may possibly be exposed to overspray 0 Clean the area thoroughly with a white cloth saturated with acetone to remove all dust or debris Cx Preparing the Gel Coat and Spray Equipment Les Thin the gel coat approximately 25 percent with acetone to get sprayable consist
79. ower tools They are as follows BAND SAW COUNTERSINKING DRILL BITS TABLE SAW NUMBER DRILL SET SABRE SAW TAP SET NATIONAL COARSE ELECTRIC HAND DRILL ACCURATE CARPENTER LEVEL RATCHET TYPE SCREW DRIVER CHALK LINE SMALL MITRE BOX 12 ROLL UP TAPE MITRE HAND SAW CARPENTER S HAMMER HACK SAW SET OF SCREW DRIVERS SET OF FILES SET OF WOOD CHISELS SET OF HOLE SAWS SOCKET AND OPEN END WRENCH SET 32 Keeling and Leveling Hull It is suggested that you purchase your kit with the keel installed Since the keel represents approximately 50 of the weight of the hull it is very difficult to handle without heavy equipment that a boat builder has available and which is not normally available to the amateur builder If you have not had the keel installed by Sailcrafter then it should be installed first This is accomplished in accordance with Section 5 8 SECTION 5 Page 3 continued 1 After the ballast has been installed it is recommended that the hull be very carefully replaced in the cradle so that all of the weight of the boat rests on the keel with the saddles of the cradle used only to keep the boat from falling Be sure you have adequate carpeting covering the cradle saddles so it does not mark the hull The whole boat should then be level
80. p 2 Before the vent hose reaches the screened fitting in the transom a loop should be made in it a size just large enough so it does not collapse the hose This is to keep any sea water from backing up into the fuel The hose must then be secured to the deck along its path with electrical ty wraps every 14 n 4 he exhaust system consists of a stainless steel flex hose a water jacketed exhaust pipe a length of exhaust hose a pipe loop muffler which is a stock unit and a thru hull fitting The exhaust system location is shown in the hull assembly drawing m he engine compartment ventilators are located in accordance with the deck assembly drawing The exhaust is a forced air system with the fan mounted on the underside of the deck on the port side aft and the intake on the starboard side Both are connected to 3 flex hose which leads to the engine compartment creating a complete air flow throughout the compartment and a 8 round the engine and bilge The output hose must lead to the lowest point in he engine compartment The input hose should lead to the opposite end and be located high in the Engine Compartment Follow the wiring diagram to connect th ngin 5 5 THRU HULL INSTALLATIONS T Bore a hole of adequate diameter for the thru hull device Item 4 through the entire hull laminate Items 6 and 7 SECTION 5 Page 10 continued 5 2 Remove the balsacore Ite
81. r galley sink shower base etc After installing the bulkheads the lockers may be installed screwing the locker shelf down to the ledge of the hull liner provided On all bulkheads and lockers that join the headliner toe in your screws through the top of the wood to the deck These need not be plugged as yen will be installing the teak trim over them and against the headliner The dish locker front and other lockers may be installed by first laying out the fore and aft line that the locker front will follow then screw a cleat to the fiberglass flush with this line Set the locker front against the cleats countersink and screw the front to the cleats Use ample glue between joints Plug Chisel off and sand the plugs flush with the front The drop bunks midships should be installed as shown in the drawing SECTION 5 Page 30 5 15 continued All shelves that are installed directly to the hull should be bonded the Full length with 3 oz of mat and 7 1 2 oz cloth The bond should be on both top and bottom of the shelves and run from 3 on the hull to 3 onto the shelves They can be set in place for bonding by screwing a cleat on the fore and aft bulkheads then setting the shelf on these and screwing it down from the top Leave all sea rail and pin rail to be installed last to keep from scratching or gouging them All bunks should have sea rail installed on the inboard edges to keep the cushions from sliding off The s
82. r glass hull or deck is the gel coat Gel coat is pure resin catalyzed and with the appropriate color pigment added The gel coat finish on your Sailcrafter Yacht is very hard and needs no maintenance except for light waxing now and then to retain the luster of the color Unlike the construction resins mentioned earlier gel coat does not harden in the presence of air It is necessary to cover the gel coat with a soluble mold release coat or a thin layer of flexible plastic such as Saran Wrap once covered curing takes place in about 30 to 45 minutes Gel coat colors like other pigmented materials are difficult to match It is recommended that Ram gel coats be used whenever possible A quart of gel coat for the hull and deck have been included in your component kit 2 4 Marine Wood Products The lumber used for the interior should be marine plywood exterior plywood or teak A D grade may be used for most construction Hardwood finished plywood may be used if a natural finish is desired Th dges of plywood panels and bulkheads will generally be finished with a strip of solid SECTION 2 Page 3 2 4 continued hardwood Grab rails toe rails winch pads and other pieces of woodwork located on the deck should be made out of oiled teak Fiberglass bonds to teak wood are not reliable because of the high oil content of this wood To bond on teak plywood which has a fir core the teak outer surface mus
83. r your understanding Many terms have been defined and explained as they are used every day in fiberglass sailboat fabricating plants It is recommended that you read through the entire manual to become completely familiar with all the terms processes and techniques before starting assembly of your yacht If during the construction of your yacht you need advice or information you may contact the Engineering Department by writing Sailcrafter Yacht Kits 275 McCormick Avenue Costa Mesa California 92626 attention Chief Engineer You will receive a prompt reply ECTION 2 BILL OF MATERIAL Defined and Explained 2l Fiberglass There are thr different types of fiberglass reinforcements a Mat b Cloth c Woven Roving Depending on the Lamination Schedule or area of construction these three types of fiberglass are combined a The fiber glass MAT is a very strong material and is designated by the approximate weight per square foot 3 0 oz mat for example However squeegeeing and brushing of the wet fitted material may cause it to tear or ball up b The CLOTH always used in conjunction with mat is most satisfactory for a finished surface The designation for cloth refers to the approximate weight per square yard 7 1 2 oz cloth for example WOVEN ROVING is used for structural purposes in conjunction with mat This is the material that provides maximum strength a
84. reas 55 Wet sand with 600 grit sandpaper 6 To restore gloss buff with harsh grit buffing compound and heavy duty polisher 6 4 1 Finishing Large Areas with Epoxy Enamel when a large area needs to be refinished it is recommended that the entire section be done with a good quality epoxy enamel Manufacturers of epoxy enamels supply application instructions on the labels of the cans and in published booklets The manufacturer s instructions should be followed since different types require different solvents and or handling The following is a typical epoxy enamel finishing system which can be used as a guide TOOLS MATERIAL Suction spray gun or Sanding surfacer if Paint brushes good required by enamel quality bristle manufacturer White cloth 100 400 600 grit wet Epoxy enamel of desired color or dry sandpaper Thinner as specified by manufacturer Masking tape Sanding block Paper Stirring sticks H Preparing the Surface 1s Prepare the surface as instructed in Section 65 2 SECTION 6 Page 4 6 4 1 continued 2 After the area has been thoroughly sanded mask off the area to be finished with tape and paper Be sure to cover all areas that will be exposed to overspray or spatter if you are using a brush 35 Clean the area thoroughly with a white cloth saturated with the thinner specified by the enamel manufacturer Remove all dust or debris Cx Preparing the Epoxy Ena
85. rface before coating is applied The ground surface must be primed before r rusting occurs For outdoor locations this normally means that the steel should be primed within a period not exceeding six hours after cleaning For indoors low humidity locations longer periods may be used The steel should be re ground if rain or condensed water wets the surface prior to priming Priming should not be done before th poxy filler is applied a 2 Epoxy Filler Apply epoxy filler where needed to the dry white metal surface and trowel smooth 3 Priming Apply one coat of Intergard 4424 4423 to the dry white metal and the epoxy filled surfaces The primer should be thinned 5 and applied to about a thickness of 1 1 2 mil For additional information on application procedures cleaning of equipment and handling precautions reference is made to a booklet supplied by International Paint Company a SECTION 3 Page 6 continued Transport and Assembly a During transportation of the keels from the foundry to the boat yard damage to the epoxy filler and the Intergard coating will occur Additional damage may also occur during the fitting of the keel to the hull b After the keel has been attached to the hull repair the damage with epoxy filler and smooth to desired contour 5 Apply a second coat of Intergard 4424 4423 as specified in Section 3 Priming to all surfaces of the keel d Allo
86. ring Outside of Structure Ta Remove all damaged fiber glass as instructed in Section 6 3 Procedure C 2 Now go to the inside of the structure and cut a piece of cardboard that overlaps the hole by at least one inch Shape the cardboard so that it conforms perfectly comes in complete contact with the hole 3 Place a piece of cellophane over the INSIDE of the cardboard the side that will come in contact with the hole and surrounding area SECTION 6 Page 3 6 3 5 continued 4 Place the cardboard firmly over the hole with the cellophane between the hole and the cardboard 5 Secure the cardboard over the hole with masking tape IMPORTANT To restore the strength to the damaged area the cardboard must be placed flush against the hole Areas that do not come in complete contact with the cardboard will be structurally weak NOTE The cardboard serves as a backing against which the patch on the outside of the structure can be applied Step 6 below 6 Return to the outside of the structure and patch the hole as instructed in Section 6 3 Procedures Dthrough G IMPORTANT Omit Step 3 cleaning patch with acetone of Procedure G in Section 6 3 for now 6 Repairing Inside of Structure Th Remove the piece of cardboard and cellophane from inside of the structure 2 with the power sander and 24 grit sanding disc remove enough of the fiber glass from the area so that at least two pieces of fi
87. s When the cardboard has been properly shaped remove it from the hole 6 Remove the wire from the cardboard dos Make a backup patch fox the hole by cutting a piece of fiber glass cloth and mat to the size of the cardboard 93 Place the piece of cloth on top of the cardboard and the mat on the top of the cloth Wet out the patch by applying catalyzed resin see Chapter 6 3 Procedure E Step 1 to the cloth and mat with a paintbrush He sure to work out all the air bubbles as you go VOS Reinsert the wire through the cardboard and the fiber glass patch SECTION 6 Page 6 continued Insert the cardboard through the hole Pull the wire toward you until the patch is flush against the hole The fiber glass cloth and mat should be in complete contact with the hole from the underneath area Place a stick across the sanded area Tie the ends of the wire around the stick to hold the backup patch securely in place This patch serves as a backing against which additional layers of fiber glass patching can be applied Allow the patch to cure When the patch has cured separate the wire from the stick Cut off the ends of the wire as soon as possible to the patch Remove the remaining visible ends of the wire with the power sander Sealing the Backup Patch Mix resin and milled fibers in equal proportions Add catalyst to the mixture in accordance with the m
88. s small and roughly contoured shape it with the sander so that a piece of cardboard can be easily inserted through the hole 2 When cleaning the area thoroughly with acetone Section 6 3 Procedure C Step 2 insert the saturated cloth through the hole and clean around th dges underneath This underneath area must be completely free of water oil and wax so that the patch to be applied there will bond properly SECTION 6 Page 5 6 3 6 continued Inserting the Back up Patch i Cut a piece of cardboard so that it overlaps the hole at least one inch on all sides 2 Insert a piece of wire through the cardboard in a U shape so that the wire enters at one end of the cardboard passes along the length on the reverse side and comes back to the front at the opposite end Su Insert the cardboard through the hole 4 Pull the ends of the wire toward you to determine whether th piece of cardboard comes in complete contact with the hole from the underneath area If the cardboard does not come in complete contact with the hole remove and properly shape the cardboard with your hands so that it conforms to the hole Then insert it through the hole again to determine whether it is flush against the hole IMPORTANT The cardboard must be removed from the hole and reshaped as many times as necessary until it conforms perfectly This procedure is necessary for the area to be restored to its original structural soundnes
89. s that are shipped to areas that have below freezing temperatures it is strongly recommended that the engine cooling system be winterized by utilizing an approved anti freeze The approved anti freezes for the Perkins Westerbeke Palmer and Atomic 4 engines are as follows DOWGUARD PYRO PERMANENT HUBBARD HALL SMITH BLUE CO PEAK TELAR PERMA STA ZEREX PERMAGUARD It is also strongly recommended that the water tanks and the head be completely drained of water including all the lines SECTION 3 Page 5 34 6 Anti Fouling Protective Coating System This specification covers sandblasting and the application of an International Intergard coating No 4424 4423 and Tri Lux T B T O anti fouling paint containing Biomet coating to the keel and underwater hull areas It should be used on all Kit Boats that have outside ballast and is optional on boats with inside ballast nies Cast Iron Keel Grind entire surface of keel to white metal White metal is defined as a surface with a gray white uniform metallic color slightly roughened to form a suitable anchor pattern for coating The surface should be free of visible mill scale corrosion products paints or other foreign material It is the intent of this specification to have a surface conforming to Steel Structures Painting Council Surface Preparation Specification 5 All sand and dust residue is to be removed from the su
90. sanded smooth and fair to blend the hull and the keel and repainted with Intergard 4424 4423 Primer over any spots where the sanding has cut through to the bare metal 9 9 1 1 The only anti fouling bottom paint that can be used on boats whose keels have been finished in accordance with this procedure is International Tri Lux T B T O anti fouling bottom paint SECTION 5 Page 16 5 9 Plumbing and Water Tanks WATER TANK INSTALLATION 1 Formica sheet shall be adhered to both sides of 3 8 plywood inside only where the tank lid is to serve as the cabin sole by application of a suitable contact cement either contact cement 2210 from 3M Company or spray contact cement No 5E 410 from Morton Company The tank drain thru hull fitting shall be installed after the installer has inspected the tank wall around the bored hole for the thru hull fitting against voids and weakness of the wall The thru hull is to be sealed with silicone sealant A plywood donut is to be used on the exterior The tank vent line thru hull if required by the plumbing drawing shall be installed in the same manner 3 The installer is to further inspect the inside of the tank against voids between the gelcoat and the laminate particularly in the corners which will lead to leaks 4 The lid prior to installation shall be fitted with the required fill fitting The fill shall be thru bolted to the lid and sealed both sides with silicone s
91. surement from the outside of the box at the radius of the flange and the box and lay this out centered on the forward side of the island between the cockpit seats Keep the bottom line of the cut out 6 above the deck The boxes are furnished with a teak trim Trim the trim to fit the box Install the box using dolphinite sealant and flat head self tapping screws countersunk You are now ready to install the teak trim SECTION 5 Page 27 5 1 2 continued Looking at the back of the frame there are slots cut from the inside of the frame across the wood to the outside These are drain holes and should be at the bottom of the box Fasten the frame by screwing countersinking and plugging the holes Grab rails are mounted on the cabin top as shown on the Deck Assembly drawing They axe fastened as follows All cabin top teak hand rails used shall have at least one stainless steel thru bolt at each end fastening them to the deck Hand rails with more than two grips shall be fastened with thru bolts as illustrated below The intermediate grips shall be fastened with stainless steel selftapping screws The eyebrow trim is pre cut and shaped to fit the cabin top Follow the scribe line on the cabin to install this After installing them some shaping and sanding may be needed to make them fair He careful you do not drill through the cabin when drilling your screw holes Mount with countersunk stainless steel self tapping screws F
92. t This also eliminates chafe of the after guy on the upper shroud To save wear and tear read up on spinnakers and then have a couple of experienced friends join you for the first couple of spinnaker drills 5 7 5 Reefing Gear Two methods of mainsail reefing roller and cringle jiffy reefing are in common use and their pros and cons could be discussed forever On boats that have their mainsheet on the end of the boom there may be a roller reefing mechanism contained in the gooseneck fitting An optional GEARED ROLLER REEFING GOOSENECK may be installed in which a handle cranks the boom around and the sail is rolled down around the boom With mid boom sheeting most people will use the optional Cringle Reef System which is well illustrated and explained by drawing STD 00 0030 This system is quite fast provides better sail shape control than does roller reefing and is definitely recommended for the racing skipper It is really up to you to figure out if you want to go to roller reefing or cringle reef After having consulted your own local experts you will know enough so anything we can add would be superfluous 8 6 Folding Mast and Hinged Mast Steed If you have equipped your boat with this optional item it is completely explained and illustrated by drawing STD 02 18201 SECTION 6 Page 1 6 1 INTRODUCTION TO FIBERGLASS 6 1 1 Composition and Properties of Glass Fibers
93. t be removed to the core All the interior and exterior wood products needed for the completion of your Sailcrafter Yacht can be acquired from Sailcrafter Yachts These marine wood products are all oiled teak and have been cut shaped rounded and sanded for immediate installation in your yacht 245 Fasteners The fasteners for all Sailcrafter Yacht fiber glass boats are passivated stainless steel Bolts for securing the chainplates to bulkheads headstay and backstay fittings to the hull are stainless steel bolts fitted to the holes in the chainplates Deck hardware such as winches genoa tracks and mainsheet travelers should be thru bolted with round or oval head bolts as appropriate Use the largest siz bolt that will fit through the holes in the hardware Toe rails cabin trim and other decorative wood can be fastened with self tapping stainless steel screws These should be long enough to protrude through the fiber glass to the beginning of the full sized threads and then snapped off flush They should be countersunk and hardwood plugs glued in place over the heads All hand rails grab rails ladder fastenings and other wood parts that take a load should be thru bolted with stainless steel bolts It is good yacht building practice to have all screw slog lined up fore and aft While stainless steel screws are not thoroughly compatible with aluminum they are the best material available for fastening to the mast or boom They shoul
94. t sand and buff For other Sailcrafter Yachts using a strut type aft bearing the strut shall be mounted in accordance with CSP 00 9051 The fuel tank is installed in its compartment by sanding the gelcoat from the sides and bottom of the compartment and filling the space between the tank and the compartment walls with Micro Balloon filled resin Mix to about the consistency of pancake batter and catalyze with no more than 2 by volume of resin Mix well before pouring Fill up to from 2 3 inches from the top of the tank This locks the tank in The fuel fill line is run in accordance with the plumbing drawing Drill the proper size hole in the deck to receive the deck fill fitting Bed the underside of the deck fill fitting with polysulphide and holding the vertical flange on top of the deck fill fitting facing forward insert the fitting and screw it down Connect the fill hose and fill SECTION 5 Page 9 5 4 continued fitting together with a hose clamp The ground wire must be installed from the fill fitting to the tank to engine ground to prevent explosion from static discharge in accordance with the wiring diagram The fuel tank vent line is led from the tank to the engine compartment in accordance with the plumbing diagram de The hose must be led continuously up so fuel is not trapped to a screened thru hull vent fitting on the transom and fastened there with a hose clam
95. t your boat is complete and ready to go into the water it is extremely important that you carefully check out your rigging and mast prior to having the boat moved to the launching facility Check the dimensions of all your shrouds standing rigging and the dimensions of the location of the tangs in accordance with the drawings provided to insure that when the mast is stepped that everything fits properly Enclosed in this manual is a Launching amp Commissioning Record If you follow the Launching amp Commissioning Record step by step you should have an easy time getting your boat ready for sea When tuning your rigging the following steps are recommended 23514 Mast 6 Under no circumstances should any of the rigging be set up bar tight For all sailing conditions we recommend that the mast be vertical and in column with the rigging firm It is very important that a knowledgeable person who understands this concept oversees the initial tuning of the mast and rigging You should be able to stand facing the mast reach out and pull on any stay and see the mast move in that direction With a light pull or push by hand at chest height this dockside starting point will have both stays of equal tension with about 1 to 2 of play in the uppers and 2 to 3 of play in the lowers The backstay and jib stay should be of equal tension and have about 1 of play If the mast is stepped on deck the rigging will be tighter than a mast stepped on
96. the hull mold The top edges of the hull and hull liner will be bonded the full length of the hull liner before being pulled from the mold After trimming the outer and inner gel face should be sanded off 1 2 from the edge the full length of the hull and across the transom Section 5 Page HULL TO DECK JOINTS 2 5 2 cl continued Before joining the hull and deck a short piece of H metal 6 8 should be slid along the joint on both the deck and hull to insure a proper fit The bottom of the H metal should be filled 1 2 to 3 4 of the way up with caulking and placed on the hull Use a rubber mallet to insure the metal is down When the H metal is down caulking should ooze out Drill a hole in the H metal with a 13 64 bit and pop rivet S Riveting Instructions The top of the H metal should be filled with caulking 1 2 to 3 4 of the way up The deck shall be placed on the hull and forced into the H metal When down caulking will ooze out Drill and rivet After riveting clean caulking before it cures Then seal rivet heads The corners and bow should then be bonded 4 oz of mat and 3 oz of cloth Then install gunnel rubber Insert bottom of rudder in bottom of H metal Use a wedge to run along top Rubber will fall into place Install corner and bow casting with machine screw in kit Then seal around castings and H metal top and bottom with marine sealer G E White to insure no
97. uld be ground until smooth and fair with a disk or belt sander using 60 grit cutting surface Any depressions should be filled with polyester body putty Ample putty should be applied to allow for some shrinkage When the putty has hardened it should be sanded in turn with 220 and 400 wet or dry sandpaper The gel coat should be applied next by using a spray gun The Freon propellant type guns are satisfactory Thin the gel coat approximately 40 percent with acetone for spraying Add one to two percent by volume of catalyst More catalyst causes the resin to set faster Curing is slower at temperatures below 70 and does not proceed satisfactorily below about 57 Temperatures between 700 and 57 may be partially compensated for by slightly more catalyst High humidity also interferes with curing After the gel coat is sprayed on a thin layer of mold release 5006 mold release liquid from Thalco Corp should be applied with the spray gun to shut out the air and permit the gelcoat to cure Curing should be complete in about two hours The release is water soluble and can be easily washed off Sand with 400 then 600 wet or dry sandpaper and finish with a buffer For additional information concerning gel coat touch up and repair consult Section 6 NOTE Ground fiber glass is an irritant to the respiratory system and a mask should be worn when machine sanding Use separate cups for gel coat and release Mix small quantities only of gel
98. uld spray finish the area with a matching color For the proper finishing procedure see Section 6 9 SECTION 6 Page 3 6 2 6 Repairing Gel Coat Crazing TOOLS MATERIALS Heavy duty polisher Harsh grit buffing compound Huffing pad Water White cloth Gel coat Sanding block Cab o sil Putty knife Catalyst Cellophane Sandpaper 100 220 400 6 600 Single edge razor blade B Preparing the Surface T Remove the crazed cracked area entirely by block sanding with 100 grit sandpaper IMPORTANT If all the crazed area is not removed it will continue to spread after the unit being repaired has been returned to normal use 2 while sanding be careful not to make ripples and indentations in the gel coat surrounding the craze If ripples and indentations do appear after the craze has been removed go to Procedure C below du If after you have completed sanding the surface the craze appears in the fiber glass below the gel coat to to Section 6 3 Fracture amp Puncture Repairs 9 If after you have completed sanding the surface there are no ripples or indentations and the craze does not appear in the fiberglass go to Procedure D below Patching Ripples and Indentations NOTE This procedure applies only if ripples and indentations appear in the gel coat as a result of sanding the crazed area Procedure Babove uM Make a smooth thick manageable putty by mixing Cab o sil and a matching gel coat
99. w complete SECTION 5 Page 8 5 4 ENGINE AND FUEL TANKS The engine should be set in prior to decking the boat however it may be set in through the main hatch if installed later Th ngin xhaust should also be set in place before the deck goes on The engine is installed on the engine bed that is molded into the hull liner in accordance with the hull drawing The propeller shaft is fastened to the engine with a solid flange For the S 28 5 36 and 5 50 the shaft is enclosed in a bronze shaft log tube which has a Cutlass bearing in the aft end A hole or slot is cut in the hull to allow this tube to go through the hull The forward end of the prop shaft tube is coupled to a stuffing gland by a short piece of Steam hose using stainless steel hose clamps at each end 6 The engine should be moved to its correct location set on its mounts and secured temporarily with stainless steel lag screws The prop shaft may now be put in place by pushing it through the prop tube from the outside and the shaft flanges coupled together The shaft should be free from horizontal and vertical pressure so that the shaft turns freely The stuffing gland should be at least 2 aft of th ngine flange in order that the packing gland can be opened for the installation of packing The prop shaft tube should then be bonded in accordance with CSP 00 9054 Then fair out the bonds by sanding Fill the small voids with body putty sand gelcoat we
100. w four 4 hours drying time before top coating Anti Fouling Coating a Apply one 1 coat of Tri Lux T B T O antifouling to all of the keel and hull b Before applying the Tri Lux anti fouling to the hull the polyester gel coat should be thoroughly sanded to provide an anchor pattern or tooth for good adhesion c Allow four 4 hours drying time d Apply second coat of Tri Lux anti fouling as specified in Section 5 a e Allow 24 hours drying time before immersing boat in water International Tri Lux is a vinyl anti fouling formulated for ship bottom use It contains Tri Butyl tin oxide T B T O as the toxic agent Unlike cuprous anti foulants it may be applied directly to a primed steel surface without the need for an additional anticorrosive coat SECTION 4 THE FOLLOWING BLUEPRINTS AND DRAWINGS SHOULD BE STUDIED CAREFULLY PRIOR TO STARTING ASSEMBLY CHAIN PLATE COVER WITH SCREWS INSTALL AFT LOWER CHAN PLATE AS PER DRAWING FASTEN FOR LOWER TO BULKHEAD SET INBOARD ENOUGH TO CLEAR TIB DISTANCE SETWEEN PLATES S APPROX 22 APT LOWER CHAIN PLATE LOWER CHAINPLATE Ar 25 14 1018 05 3153 45 35 33 106 553 ILON X2O1S 3 0379002 JON 38 518 3AOHHO 80 Q3WOBNHO 6
101. y 9 YIA 0770 07 SS VA fe I9 HINI LNOIVELS Ss via 8 T 2 7 SS 75 ANINDAVETS HOOO OH NO 21 1 8 5 9 3 5 SLOW NYOY SANG SS Ga 2 POS CUTE RE 2 e LR BZANON 5NI AWYuG af F 22 Z PERL ewe CANS aem OV SPOT EY 4 E ANSE WE 7 P DECS OC COC DUIE SAL uA c ge e 5NI AAYHG 024 8 3 10 7030001 LSW 52 OQVNOX0 amyl bay noya L ss SNOT Eb 0 33104 o LNW 00 Wny da 2 DOW QNO t2 ANIM SS aha w2 0yQ n BAIMS Gam HOd NID oL 5 32 099 ayns 9 5 MNM 3 21 ON Sma RR 31 9 En roy ABP CHEWS SZ 40 m9 AMORES PED IAS 8 8 vom 03 0 Sree MAS FNS 4977 52 uu ADAE a CAP 2 LEE POY SP 27222 DOG JUD 7 JM vo gn AA 7 27872172777 X VES WOOT SECTION 5 Pag

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