Monday, March 17, 2008

4. Glue the Seams - Clip the Wires

The hull is basically all wired together now and it's time to start putting epoxy into all the seams. I mix the standard 2 parts epoxy to 1 part hardener and pour it into the syringe. Then I carefully run the tip down each seam - giving it just the right amount or pressure so the epoxy complete fills the varying width seams.





Seams after first round of fill.




Let it dry overnight (or a couple days) and then it's time to clip the wires. Yep, all 200 or so of them. This can be tricky at times because the wire can get kinked on the inside and not pull through very easily. I used a variety of techniques including:

a) clipping one end of the wire very close to the hole, and then wiggling and gently pushing the other end inward (until the clipped side slid inside the boat, then angling the wire down or up so it followed the natural curve inside and slide right out.

b) grasping one end with a pliers, then placing the rubber end of my side cutter under the head of the pliers (to give it leverage) and slowly pulling the wire all the way out.

What you want to avoid is pulling so hard you damage the wood around the holes or gouging your hull with the head of the pliers.




Once the wires are all pulled you can completely coat the hull with epoxy. Pygmy recommends using a 1/8" foam roller, but I found the rollers tended to leave too many air bubbles or caused drips. (Which you'll see in a photo a little further down.) I would have to keep brushing the epoxy over and over again with a paint brush to knock down the air bubbles and eliminate the running.



Here you can see a close-up of some of the epoxy drips and runs.




I eventually decided to sand all these blemishes down smooth before applying another coat of epoxy completely with a good paint brush (being careful to continue brushing the sloping sides for about 30 minutes after applying) and this virtually eliminated the air bubble and drip problem.

The final result (before applying the fiberglass) was a pretty nice look:



Next time . . . Applying the Fiberglass.

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