Now I start on the decks. I used the temporary shear batten to mark off templates. I then used the templates to cut mirror image templates. I installed these to check the fit. Here I've traced the templates on good plywood and cut it out. I'm smoothing the cuts. Notice that I am wearing hearing protection, eye protection, and a dustmask. |
Now I join the deck halves. I really want to make sure the epoxy fills in the joint. All too frequently, if I just wet the plywood, it soaks the epoxy up leaving a gap and a very weak joint. I do the following:
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I assembled the forward deck using the same method as the after deck. |
Here is the after deck with the #5 beam installed. I ran into problems with installing the #6 bronze screws to secure the beam. First I did not make the tapered holes deep enough and the screwdriver did not fit the head well enough for putting a lot of torque on the screw without chewing it up. I had to back out two chewed up screws and install new ones. Still the beam did not appear to fit tightly to the deck so I set up this clamp structure as shown. |
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Here is the finished aft deck assembly with the #5 beam trimmed to accomodate the temporary shear batten. |
The forward deck is placed on the boat for close fitting. I filed and filed and filed some more before quitting for the night. |