So with little fanfare, Pete, Brady, Sean, and the Toddler came by to give the el-rollo treatment to the considerably heavier hull. So little fanfare in fact, that my photographer (who stated she couldn’t help lift due to her being the photographer) didn’t snap any shots. Ah well.

So first she was back on her lid and on the jig (in combination with the uber sawhorses assembled underneath):

Then add some baby-poo:

Then finish out the cut to near the transom, which is to be finished with a handsaw:

Or was that phenolic balloons and silica…

Knock it down:

Then recoat, though I did a rather ass-like job:

Then sand again…

Then forget to take photos on that sanding.

Then slob on ANOTHER coat, this time with a little silica, microspheres, and a little talc to make it sand nicely.

Then forget to take photos of the coat.


Then bust out the quickfair for the low spots, mix up some microsphere and silica goodness for the fairing of the transom and the aft end of the bottom to remove the tape induced hook:

Over the past week Ive burnt through roughly 75 50 grit sanding pads, 10 sheets of 60 grit stick on 1/4 sheet, 4 sheets of 9×12 50 grit, and a roll of carpet tape. Oh, and my rotator cuffs. Its been a good deal of work since I tried to longboard most of it. As it turns out, that takes a LONG time. Longer than I have. I got back aboard the random orbit sander wagon, although it has left me with a wavy surface. Thats not necessarily due to the sander, moreso due to my inept, random, unfair, and anti-smooth application of fairing compound. Do not, under any circumstances, have me do your drywall.

For the first time in about 3 weeks, I had tasks other than fairing. Let me tell you, what a nice change of pace…. Above you can see the current state of our subject in all her post-deadline glory.

Well I laid on another batch of quickfair from System 3, and needed it to harden up, so I started pecking away at other tasks. I also had a lift that wasn’t going according to plan (non-square pads right at the transom) so I needed to remove some humps and bumps to get it right.

Under the boat with the drill we went:

I used a piece of scrap with a hole centered at 3″ and bored for a pencil. Marked out all the interior lines per plans, then drilled holes adjacent to them on the inside. These holes were then connected with a straightedge and re-measured for squareness on the outside of the hull.

Transom curves marked out:

Same goes for the bottom (excellent no-look photography):

And now, ladies and gentlemen, the scariest cut I have made on the boat to date:

Onward with the tools, I used the circular saw to hack the straight lines, and used the jigsaw VERY SLOWLY to cut the curves. These are by far the smoothest curves I’ve ever cut:

Then finish out the cut to near the transom, which is to be finished with a handsaw:

This is a particularly good time to see just how good your craftsmanship is. All of your construction transgressions become very apparent when you cut directly through the joints you made many moons ago. Unfortunately my camera was of the opinion that the towels in the background made a better focusing topic, but you do still get a good view. Note the plywood joint, the fillet, the glass layers, the rounding of the ply to accept the glass on the outside, the filler making the edge for the transom, and filling the atrocious hack job of a stern section I made:

After these festivities (and lunch) I finished out that lift where the plywood had dipped. Its the lovely quickfair brown. Unfortunately our weather went from 90 and sunny to 58 and rain, so the quickfair didn’t harden up in the 2 hrs advertised. I will let it set until I get back from work:

So the day was winding down, nothing was curing to sand, so I took up another of the need-to-do projects, the rubrails. Jacques reccomends using 6mm ply laminated in 3 layers, so I started the process. I have a bevy of clamps on loan from a friend, but as in all boatbuilding, I don’t have anywhere near as many as I need to do both sides, so I just got one side glued up tonight:

I decided life is to be spent enjoying it, not quabbling over a mirror finish. To hell with fairing, lets prime!

I laid on System 3 high build primer ( WR-155 ), one coat one evening, then two coats a day later. This had two different reasons. First, thats all the time I had. Second (and this might have been more about justifying it, but it sure sounds good on paper), I think the bottom layer cured up a little, which makes it harder to sand through. Who the hell knows.

You can see the wavy lines, but I dont care:

Here is a considerably more finished looking transom, almost like its supposed to look:

I then proceeded to longboard this for about 8 hrs. It ended up with a bit of orange peel/knockdown drywall texture. Nice to fair into, but just more work, I think. Alright, Im sick of longboarding, so out came the ROS, vac attached, and 120 grit disks.

Did I mention I left the camera inside?

Everything ended up smooth, but still with some waves, no hard edges to the fills, but you can see some altitude changes. Ya know what? WHO CARES!! This isn’t a $100,000 mahogany runabout. Life isn’t about finishes and perfect mirrored surfaces. This is a boat, first and foremost, that will be used daily. I mean that. My neighbor put 208 hours on his boat in a year. We will rival that, as the fishing season is 9 months long, not to mention I have friends in various places on the lake which requires transportation.

I don’t want to sweat a little nick or rub here and there. I want to be able to dock anywhere. I want to be able to put it on the beach. I want to be out in the salt sometimes. I dont want a boat that isn’t USABLE.

Oh, and I forgot the camera for another phase.

Well here is where the camera comes back in, photos by SWMBO:

What happened? Its like a peacock! She has sprouted colors everywhere!

The bottom paint is West Marine BottomPro in red, laid on by myself (1st coat) and Jerry from down the lake (2nd coat). Massive mixing issue with the first pint. Get it mixed at the shop. If it has any solid masses in it, switch to another can, use the better paint, and have that shaken or replaced. It went horribly due to the solids coming out of solution. Jerry laid on the 2nd coat, but the 2nd can was fully suspended and required minimal mixing.

Topside paint is Kirby’s Grey-green. I highly reccomend Kirby’s for one particular reason; this stuff is literally fun to paint with. It lays out smoothly, it cleans up easily, it hides brush strokes well, and with a little penetrol, becomes very smooth. It is a semi-gloss to hide imperfections and the inevitable damage later. A little goes a Loooooong way with this paint. I used less than a pint for one full coat.

Two coats of bottom paint, one coat of topside. Due to this being the first of its kind built, I am not putting the waterline in place until its actually in the water, loaded. Thus the lines are a little here and there. but you get the general idea.

Once again I recruited the crew, Pete, Brady, Shayne, Ron, Sean, Tom, and myself (with a little assist at the end from Shayne’s girlfriend Stephanie, the greatest cake-maker in the world). These people have been a tremendous help by coming over at short notice, giving of their Father’s day to help me flip this thing. On with the show!

There is a ton of interior bracing built of 2×4 inside the boat to allow rolling it on the gunnels like this:

Add some 10′ doug fir studs for handles:

Stephanie helping out, and getting it up on the trailer:

All in all a fun event. Big thanks to Jerry, whom I had planned on purchasing the trailer from, but was unable to get bunks built. He saw the issue and built those monsters from supplies he had at his house midday sunday. Huge help, and I hope he doesn’t mind that I just drove down and stole the trailer from him.

Thanks again to everyone that helped.

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