631 replies to this topic

[Kevin Farrar]

The nineteen mylar deck mold templates have been drawn and cut. We will start cutting the plywood sections this weekend and with any luck the pieces we made before I went traveling the world will also start getting glued in.
Happy New Year,
Kevin

[Kevin Farrar]

Well i didn't get around to cutting the deck mold stations. I did get the section "C" upper bulkheads, de-watering boards and supports cut and installed this weekend. I still need to tape them in but they are at least glued in place.
Kevin

Attached Files

•  IMG_1355.JPG   76.89K   45 downloads
•  IMG_1357.JPG   80.78K   65 downloads
•  IMG_1359.JPG   85.77K   69 downloads
•  IMG_1360.JPG   87.5K   57 downloads

[Ryley]

Looking good Kevin. Sorry we didn't catch up over the holidays - will see you soon, I'm sure.

Lance

[Kevin Farrar]

This morning's "dawn patrol" started cutting the plywood for the deck mold. Plenty more stations to go and I still need to chase down the rib bands.
Kevin

Attached Files

•  IMG_1364.JPG   102.71K   24 downloads

[Kevin Farrar]

The deck mold stations are starting to get put together. All of them are cut and the process of pre-rib band fairing is underway. We need to extend the bagging table (now deck strong back) to accommodate the full length of the deck. The rib bands are supposed to be cut but I havn't seen them yet. The weather up here has sucked this past week so i'm not really surprised if they are not planed and slit to size yet. Building a mold nearly the same size as the hull is requiring some creative reorganization of the shop space but we think its all going to fit.
Kevin

Attached Files

•  IMG_1365.JPG   89.54K   36 downloads
•  IMG_1366.JPG   79.76K   32 downloads

[Ryley]

Kevin, I know you've got a lot on your plate, but do you have a tentative schedule to see this beauty in the water yet? Or is it still too soon?

[Kevin Farrar]

Well in the last couple of week the shelves from hell have been built and the junk that was taking up an enormous amount of space in the shop is piled on them. The lay-up table has morphed into the deck strong back and the faired deck mold stations now sit upon it. The stations that contain the cabin blister have been joined together so that that section can be moved side to side so that we can install the foam core without having to climb on the rib bands. The rib band for the cabin will start going in tomorrow. Both molds actually fit in the space with reasonable room still left to move around.
Kevin

Attached Files

•  IMG_1369.JPG   116.53K   76 downloads
•  IMG_1371.JPG   124.01K   93 downloads
•  IMG_1370.JPG   99.37K   77 downloads
•  IMG_1372.JPG   73.17K   72 downloads
•  IMG_1374.JPG   69.11K   58 downloads

[Conny71]

Kevin,

Why the use of plywood instead of MDF for this mold?

[Kevin Farrar]

Hi Conny71,
We decided to cut the deck mold part ourselves instead of having them C&C cut as we did with the hull stations. We felt that the ease of working with the plywood was worth the difference in price. We will be using the same technique as was used in the hull so getting a sheet rock screw to bite the first time is important. The other thought in deciding to go plywood was the rib band to mold station epoxy bond would be more secure.
Kevin

[Kevin Farrar]

The final leveling of the strongback/table was laser leveled to within a millimeter and then each station checked as well. The stations, with the exception of those associated with the cabin blister, have been secured to the strongback. We quickly checked the shear line with a long rib band and it looked really fair. This afternoon the first nine rib bands were glued into the top of the cabin blister. After these rib bands cure in place they will be trimmed and additional bands will be fitted to complete the blister. Sometime this next week the oven will be dusted off and the foam will be heated and will start to be installed. Once the foam is in the blister the cabin section of mold stations will be realigned on the strongback and secured. The remaining bands will then get glued on with the deck foam to follow.
Kevin

Attached Files

•  IMG_1378.JPG   83.28K   48 downloads
•  IMG_1379.JPG   101.4K   62 downloads
•  IMG_1381.JPG   101.95K   60 downloads
•  IMG_1382.JPG   75.78K   43 downloads

[Kevin Farrar]

The cabin blister ribs bands are finished being installed.
We fired up the oven and decided to turbo charge the heating by wiring in an infrared lamp which has brought the temperature up above the melting point of the foam. Having said that, the thermostat is now a useful devise.
The high density inserts were pre-fitted in the foam panels before heating and the foam starts going in the top of the cabin.
Kevin

Attached Files

•  IMG_1383.JPG   112.18K   21 downloads
•  IMG_1385.JPG   111.17K   29 downloads
•  IMG_1387.JPG   111.78K   36 downloads
•  IMG_1388.JPG   98.63K   40 downloads

[Kevin Farrar]

More photos.


We ended up snapping a couple of the smaller pieces where high density inserts were glued to regular density foam. We replace those small panels with solid high density foam and the difference was only a few grams due to the size of the pieces.
The compound curved cabin top was completed and the flat sides bent in and attached at the cabin chine. The inside of the blister is being faired as I type and this afternoon the cabin portion of the deck mold will be re-aligned on the table and secured in place. With any luck we might get a rib band or two on the mold for the deck foam.
Kevin

Attached Files

•  IMG_1391.JPG   85.84K   44 downloads
•  IMG_1395.JPG   80.64K   49 downloads
•  IMG_1397.JPG   108.05K   51 downloads
•  IMG_1399.JPG   73.79K   37 downloads

[Kevin Farrar]

After the cabin blister section of the deck mold was secured in place we took the better part of a day to make-up and install supports that held the cockpit face portions of the mold at 90 degrees to the table surface. Although time consuming this step brought that part of the mold into near perfect fairness. That being done, the rib bands were install without difficulty. This morning the wire ties and clamps were removed and most of the bands have already been covered with mylar release tape. The foam has all been cut for the cockpit face to deck radius and the oven is heating up. The radius pieces should start being formed into shape within the next hour.
Kevin

Attached Files

•  IMG_1400.JPG   90.47K   16 downloads
•  IMG_1403.JPG   90.08K   14 downloads
•  IMG_1404.JPG   100.56K   20 downloads
•  IMG_1409.JPG   118.71K   30 downloads
•  IMG_1410.JPG   107.81K   31 downloads
•  IMG_1415.JPG   99.74K   23 downloads

[Kevin Farrar]

Hot off the press.
Peter and Ed have been busy today shaping the foam for the cockpit deck radius. When all the pieces are bent to the radius they will be fitted and glued together . The starboard side is done and tomorrow its on to the port.
Kevin

Attached Files

•  IMG_1418.JPG   107.17K   34 downloads
•  IMG_1419.JPG   81.5K   32 downloads
•  IMG_1420.JPG   89.31K   37 downloads
•  IMG_1421.JPG   91.66K   34 downloads

[fdsailor]

Looking good. How's the weight panning out? You measuring bits as they go on against a detailed weight estimate?

[Ryley]

Looks really good Kevin.

[Kevin Farrar]

"Looking good. How's the weight panning out? You measuring bits as they go on against a detailed weight estimate? "

We have been checking the weight as we have gone along and the parts that have been weighed have all been close to Jim's targets. I guess the acid test will be after the deck is bond and we can weight the nearly completed hull. This near complete weight will be done prior ro the outside of the bottom getting laminated.
The 2011 class rules have been posted on the ORC.org website. The changes to the rule ( I believe) will give us a little more room to come in near minimum.
Kevin

[Kevin Farrar]

The deck radius is slowly getting fitted. We are telling ourselves that fairing the radius will save time later. I hope that is right because these things are taking forever. The flatter cockpit sides and deck should go much faster.

Attached Files

•  IMG_1428.JPG   96.77K   50 downloads
•  IMG_1429.JPG   118.33K   55 downloads
•  IMG_1430.JPG   97.58K   44 downloads

[gone]

Damn, you do some BEAUTIFUL work!!

The smoother your work is at the start, the less you will need to fair later.

[Ryley]

Damn, you do some BEAUTIFUL work!!

The smoother your work is at the start, the less you will need to fair later.

Kevin's a perfectionist. If you can afford one, I highly recommend one of his sails. The finish work is second to none.

[Kevin Farrar]

It's been nearly weeks since an update. We have been pretty busy working on the deck. This series of photos shows the piece starting to go together.
Kevin

Attached Files

•  157.JPG   102.91K   19 downloads
•  158.JPG   114.6K   23 downloads
•  161.JPG   93.44K   23 downloads
•  162.JPG   99.6K   19 downloads

[Kevin Farrar]

We also have gone back to working on the hull because there are a number of steps that need to be completed before we can flip the deck onto the hull. In these shots the inner-gunwale foam is glue in. These foam parts will be glassed over and then ledger pieces made to become the shear clamp. Once the inner-gunwale is glassed and the hull between the shear gets a few temperary supports the hull mold above the chine will be removed.
Kevin

Attached Files

•  164.JPG   78.43K   21 downloads
•  165.JPG   82.01K   23 downloads
•  175.JPG   90.44K   15 downloads
•  176.JPG   71.13K   14 downloads

[Kevin Farrar]

Tom fine tunes a piece of foam destined for the fore deck.
After the foam is heated and fitted all the lead dive weights in the shop are placed on the foam as the glued parts cure. The deck core is sewn to the mold to convince the foam to stay in place and Ed and Peter are almost finished with the pre-lamination fairing. Lamination should happen next weekend if not sooner.
Kevin

Attached Files

•  166.JPG   138.76K   26 downloads
•  168.JPG   106.65K   31 downloads
•  169.JPG   114.64K   35 downloads
•  170.JPG   78.01K   33 downloads
•  172.JPG   83.55K   36 downloads
•  173.JPG   83.64K   28 downloads

[jim lee]

I've been watching this build and I keep wondering, what happens when someone wants a sister ship? Is there any thought to a second boat? Would the second one be able to leverage on what you've already accomplished or is this one-off only?

-jim lee

[Kevin Farrar]

The tooling (all of it) is definitely for sale. Jim and I have discussed it awhile ago and think that the mold is good for up to another four to five boats. The amount of time saved in a second or third boat using this tooling would be amazing. The deck mold should be available in about a month if not sooner. The pieces and parts tooling along with the mylar templates are available now.

As for leap frogging the design I think would come to refinements in what Jim comes up with in rudder and keel design which at the moment is not finalized.

Jim Donovan, of course, holds all rights to the design and anyone wanting to purchase the molds would first need to contact Jim and buy the plans / rights to produce.
Please contact me if you would like to discuss.

Best regards,
Kevin Farrar

[Trevor B]

The deck core is sewn to the mold to convince the foam to stay in place

What, exactly, do you mean by "sewn"?

[Kevin Farrar]

Hi Trevor B,
We drill two holes through the foam on either side of a rib band then scratch a shallow grove in the foam between the holes. We then take a piece of #40 Dacron leech line and poke the ends of the line through the holes using a sail needle or piece of wire. Both ends of the line are drawn through the foam and knotted together or tied to sheet rock screws depending where we are fastening the foam. When we are sewing in the middle of a section between stations the end of the line are knotted around the rib band then small wooden wedges are pressed together (two opposing wedges works best (not shown)) tensioning the line and drawing the foam to the rib band. Near a station the screws are used to tie the foam down. The line pulls into the groves so that the line lays beneath the laminate and does not make a bump. The line, groves and holes fill with epoxy and become part of the boat. After one side of the laminate is complete the lines around the rib band are cut so the part can come off the mold. Once the part is off and flipped the lines are trimmed to the surface level and any remaining void filled with the laminate and epoxy.
Kevin

Attached Files

•  20090904_IMG_0001.JPG   89.18K   57 downloads
•  20090904_IMG_0002.JPG   93.92K   51 downloads

[Trevor B]

Thanks.

[jim lee]

The tooling (all of it) is definitely for sale. Jim and I have discussed it awhile ago and think that the..

Sorry no, we have plenty of tooling. Heaps of it laying around here. I was just wondering because your process is so different than ours.

-jim lee

[bruno]

Kevin: I hope that I'm not repeating an earlier question in this thread, but why did you decide to use a female hull mold rather than a male? Obviously the sewn foam is cleaner and requires less bog than a screwed/bogged core. Perhaps it's also fairer due to less density variance? Impressive project.

[Kevin Farrar]

Hi Bruno,
A case can be made for most all methods. We went with the idea that getting the structure in the boat first was our best option. Once the deck is bond to the hull the boat will be stable when we roll it to laminate the bottom.
Kevin

[Kevin Farrar]

With the help of Peter, Roger,Walter, Tom, Ed and Pat the underside of the deck was laminated yesterday. Ed took a series of high definition photos (on a timer I think) of the six hour process. When we get those photos in a web friendly file size I'll post some of them.
Kevin

Attached Files

•  183.JPG   93.68K   71 downloads
•  184.JPG   119.85K   77 downloads
•  186.JPG   118.7K   64 downloads

[SA Lurker]

Wonderful little boat.

Obviously a labor of love.

What will you name her?

[Kevin Farrar]

The glassing of the inner-gunwales was finished today with the exception of the part between the carbon transverse keel frames ( about 350mm). This means that tomorrow we can cut back the mold above the chine at the bow transom 185mm aft of point zero and start the laminate need to accept the forestay assembly and sprit tube. All this wants to be complete before the deck is flipped and fitted to the hull.

Measurements from the plan profile of the actual hull have been taken and transferred to the deck and the "cut line" has been splined / drawn on the underside of the deck.

After considerable head scratching and discussion we have decided not to remove the upper portion of the mold above the chine until after the deck is bonded. We will be removing only the rib band that follows the shear as with this piece removed we can attach the deck without mold interference and not take a chance that the shear flare will do something funny.

The triangular structure between the companionway bulkhead and the deck cabin blister intersection is in place and partially glass in. This part also should be finish this weekend along with some fairing of the underside of the deck.

More soon.
Kevin

[Kevin Farrar]

Clamping the last of the inner gunwale, it seems you can never have enough clamps. The same shot yesterday after the uni's and biaxial were laminated.
This morning the forward portion of the hull mold was removed so that we could access the bow transom. We flush cut the hull back to the bow transom then laminated the two sides together above the chine. The build-up for the sprit tube and the forstay assembly were included in this process.
Kevin

Attached Files

•  005.JPG   97.92K   65 downloads
•  007.JPG   96.84K   80 downloads
•  009.JPG   103.64K   104 downloads
•  014.JPG   115.27K   97 downloads

[Conny71]

That's high tension green tape holding your peel ply in place, about the same as vacuum bagging?

[Kevin Farrar]

Hi Conny,
Not exactly the same as the vacuum pump. This particular laminate would have required the bagging tape to cross foam which would have leaked like a sieve. We instead wet out the cloth on a table then applied the cloth around the bow transom. When ever it is practical we are bagging, but when not, pre-wetting of the cloth and weighing the material dry prior to laminate to ensure that excessive resin is not used is not unreasonable.
Kevin

[Kevin Farrar]

The sprit tube was lined up with the laser and the holes cut through the bow transom and the bulkhead aft of it. We machined the sheave plates for the forestay assembly and installed those as well ( photos next post ). The rectangular holes in the bow transom are for the sheave plates.
Kevin

Attached Files

•  015.JPG   92.09K   45 downloads
•  019.JPG   113.3K   71 downloads
•  020.JPG   85.63K   79 downloads
•  021.JPG   88.62K   66 downloads

[us7070]

Damn, you do some BEAUTIFUL work!!

The smoother your work is at the start, the less you will need to fair later.

Kevin's a perfectionist. If you can afford one, I highly recommend one of his sails. The finish work is second to none.

+1

[Kevin Farrar]

The forestay sheave assembly has been bonded in and the first two stainless steel fasteners are in the boat.
We got a coat of fairing on the underside of the deck. We still to clean up the area where the cabin blister joins the deck and the gussets on the fore side of the companionway bulkhead.
The part under the bag and in the other photos is the cabin hatch slider tray which will be bonded to the cabin ceiling on which the hatch slides in and out. This part will get trimmed down quite a bit from what it looks like in the shots. We will start it's fitting process in the morning.
Kevin

Attached Files

•  001.JPG   123.22K   92 downloads
•  002.JPG   105.49K   86 downloads
•  003.JPG   112.08K   59 downloads
•  005.JPG   96.01K   55 downloads
•  006.JPG   89.49K   45 downloads

[Steam Flyer]

The sprit tube was lined up with the laser and the holes cut through the bow transom and the bulkhead aft of it. We machined the sheave plates for the forestay assembly and installed those as well ( photos next post ). The rectangular holes in the bow transom are for the sheave plates.
Kevin

umm... please tell us you're going to put a pointy front on it...

seriously, that looks beautiful and the hatch looks to be lighter & stronger than any companionway structure I've seen. This is going to be an AWESOME boat!

FB- Doug

[fullsail]

I was a bit slow on this one, but of course a pointy end makes sens now.

[Kevin Farrar]

The bow transom is 185mm aft of the actual stem. We will be adding a glass covered foam "pastie" which will cover the sheaves and bring the boat to full length.
Keviin

[Kevin Farrar]

We've been busy the last couple of weeks. Here is a short description of whats in the photos.

Hatch runner screwed to the side of the slider tray prior to installation.
Hatch getting dry fitted.
Hatch tray bonded to the underside of the cabin blister.
Keel washers bonded to transverse keel frames.
Shroud base reinforcement clamped the the transverse frames.
Shear clamp bonding flanges which have been shape to follow the changes in the curve and intersection angle of the deck / hull join.
The underside of the deck is sprayed with 545 primer (finished surface).

At this point all the shear clamp flanges are made and trimmed and the deck is "mostly" popped free of the mold. We have cut and fitted some of the temporary (wooden) supports that will keep the deck in shape while it gets flipped and then fitted to the boat. There are several parts and pieces which we need to finish up before the deck is bonded but the deck should be off the mold by the weekend.
Kevin

Attached Files

•  003.JPG   89.96K   40 downloads
•  004.JPG   101.64K   59 downloads
•  010.JPG   102.06K   66 downloads
•  016.JPG   139.63K   70 downloads
•  017.JPG   111.87K   61 downloads
•  021.JPG   99.87K   55 downloads
•  023.JPG   124.91K   52 downloads

[windseekeryachts]

We've been busy the last couple of weeks. Here is a short description of whats in the photos.

Hatch runner screwed to the side of the slider tray prior to installation.
Hatch getting dry fitted.
Hatch tray bonded to the underside of the cabin blister.
Keel washers bonded to transverse keel frames.
Shroud base reinforcement clamped the the transverse frames.
Shear clamp bonding flanges which have been shape to follow the changes in the curve and intersection angle of the deck / hull join.
The underside of the deck is sprayed with 545 primer (finished surface).

At this point all the shear clamp flanges are made and trimmed and the deck is "mostly" popped free of the mold. We have cut and fitted some of the temporary (wooden) supports that will keep the deck in shape while it gets flipped and then fitted to the boat. There are several parts and pieces which we need to finish up before the deck is bonded but the deck should be off the mold by the weekend.
Kevin

Hi Kevin,
Excellent progress... You are catching up with our boat.
Well we started spending some time on the boat again as well.
The bulkheads minus the keel support frame has been installed to the boat. Next production of keel support.
In the mean time mast is being readied and Pauger is checking some details with Jim. Also all equipment has arrived in the yard.
Looking fwd to taking the boat out of the mold...
I will post some pictures soon as well.
cheers

[Ryley]

Coming up quickly on the 1 year mark...

[Kevin Farrar]

We got the deck fully released from the mold this afternoon ( it took some doing). I was able to stand in the companionway opening and lift the deck up without damaging my back (a very good sign). We have sails in the loft that weigh more than it.
Kevin

[Kevin Farrar]

It flipped without anything breaking. Well, a couple of the temporary glue joins popped on the wooden support cradle - but no big deal. It's right side up!
Today the lifting bridle set-up was screwed to the ceiling and adjusted and I got most of the strings and excess putty cleaned off the exterior of the deck. Next is trimming the cockpit front / cockpit sole intersection and final fairing of the hull / deck join. The goal is to have the two parts stuck together this week. We still have some minor things to complete inside but nothing that should hold us up.
It's starting to look like a boat.
Kevin

Attached Files

•  002.JPG   91.62K   56 downloads
•  003.JPG   114.41K   74 downloads
•  008.JPG   109.38K   79 downloads
•  009.JPG   95.76K   78 downloads
•  010.JPG   115.43K   79 downloads
•  016.JPG   102.64K   67 downloads

[Heriberto]

The forestay sheave assembly has been bonded in and the first two stainless steel fasteners are in the boat.
We got a coat of fairing on the underside of the deck. We still to clean up the area where the cabin blister joins the deck and the gussets on the fore side of the companionway bulkhead.
The part under the bag and in the other photos is the cabin hatch slider tray which will be bonded to the cabin ceiling on which the hatch slides in and out. This part will get trimmed down quite a bit from what it looks like in the shots. We will start it's fitting process in the morning.
Kevin

This hatch detail is very impressive Kevin. What did you use to set it up? Really beautiful work. What laminate did you use?

[barefoot children]

The sprit tube was lined up with the laser and the holes cut through the bow transom and the bulkhead aft of it. We machined the sheave plates for the forestay assembly and installed those as well ( photos next post ). The rectangular holes in the bow transom are for the sheave plates.
Kevin

When i did a similar job, I put a crash box up there between the bow transom & the bulkhead aft about 1' high just in case your false bow gets penetrated

[Kevin Farrar]

Hi Heriberto and Barefoot,
The hatch tray consists of uni and bi-ax cloth. The drain channels are 5 alternating layers and the large pan area is just 3 layers. We also added narrow reinforcement along the slider pieces to stiffen and allow the fasteners to bed.
The bow "transom" is 185mm aft of the stem and is made up of several layers of cloth plus additional local reinforcement. Forward of this, out to the stem, is solid foam which will also be covered in cloth. Aft of the bow "transom" is an air tank which is about 250mm above the inside of the hull and extends about 800mm aft.

In the photo's:

The shear clamp flanges getting glued in proving once again that you never can have too many clamps. ( There is now a clamp shortage in Southern New England)

The deck is bonded with weights, clamps and sticks.

A view from the port aft quarter with the bonding stuff cleared off.

Our first look at the "BOAT" with the upper portion of the hull mold removed.

Kevin

Attached Files

•  003.JPG   126.78K   84 downloads
•  005.JPG   100.63K   90 downloads
•  018.JPG   104.22K   85 downloads
•  021.JPG   96.64K   97 downloads
•  027.JPG   111.5K   105 downloads
•  028.JPG   116.79K   143 downloads
•  029.JPG   106.29K   150 downloads

[barefoot children]

Hi Heriberto and Barefoot,
The bow "transom" is 185mm aft of the stem and is made up of several layers of cloth plus additional local reinforcement. Forward of this, out to the stem, is solid foam which will also be covered in cloth. Aft of the bow "transom" is an air tank which is about 250mm above the inside of the hull and extends about 800mm aft.

Kevin

Thanks for the info Kevin. On mine I don't have the false bow, so my crash box goes right up to the pointy end.

[007]

Looks like it's coming along Kevin. Let me know when the next beer drinking work party is scheduled, if you could use an underqualified but thirsty assistant one night during the week at the loft.

[Kevin Farrar]

The pointy end is attached and fairing started along with hours spent on shaping the gunwale. It won't be to much longer and we will glass the deck to the topsides.
Kevin

Attached Files

•  002.JPG   106.57K   63 downloads
•  006.JPG   110.88K   73 downloads
•  016.JPG   109.27K   79 downloads
•  017.JPG   103.06K   85 downloads
•  019.JPG   69.93K   70 downloads

[Kevin Farrar]

A very successful weekend. We prepped the boat Saturday and glassed the deck yesterday.
This morning I took my first walk around the deck.
Kevin

Attached Files

•  001.JPG   114.65K   79 downloads
•  004.JPG   104.93K   94 downloads
•  007.JPG   117.87K   107 downloads
•  009.JPG   97.04K   89 downloads

[Joesailor]

Hi Kevin,

Cool boat, can't wait to see it. I purchased a Viper last year and doing well with it. I will be in New London in a few weeks for the F5 NAs. Hope to catch up with you.

Joe H. Jr

[MacGyver Tech]

Hi Kevin, Boat looks great. Can't wait to see it and sail it.

Mark Grosby Jamestown

[Kevin Farrar]

The fairing process is moving along. The second coat of ballons has been allpied to the deck join and the foredeck toe rails have been installed. We still need to do some trimming in and around the cockpit and companionway. We will spray 545 primer on the topsides and deck in a couple of weeks and then roll her over.
Kevin

Attached Files

•  001.JPG   105.57K   76 downloads
•  002.JPG   90.08K   85 downloads
•  003.JPG   74.73K   67 downloads

[Conny71]

How Does your forestay attach with the round tube right there? The project looks great, you have to be looking forward to splashing it and enjoying the end result.

[Kevin Farrar]

Hi Conny,
The forestay will end with a single block or timble at it's lower end on this GP26. There are two sheeve plates sets now buried in the bow foam block foreward of the bow transom. A piece of line or wire will terminate at one plate pin then travel upward to the single block or timble then return to the other plate which has a 75mm sheave. From here the line leads aft. Earlier posts have photos of the plates before they were coverd in foam.
Kevin

[quasi-expert]

Hi Conny,
The forestay will end with a single block or timble at it's lower end on this GP26. There are two sheeve plates sets now buried in the bow foam block foreward of the bow transom. A piece of line or wire will terminate at one plate pin then travel upward to the single block or timble then return to the other plate which has a 75mm sheave. From here the line leads aft. Earlier posts have photos of the plates before they were coverd in foam.
Kevin

Seems like a lot of stuff changed with the new rules. I'm pretty sure in within the old rules you weren't allowed to adjust the forestay while sailing. is it allowed now? if not what benefits are you expecting from this setup? making raising the mast easier?

[Kevin Farrar]

Hi Quasi,
The thought is that we will load and unload the rig with the forestay. The rule still does not allow adjustment to the forestay while racing. This is a far more cost/wieght effective way of tensioning the rig than other options. The lock off cleat will be below deck with the tail able to reach one of the winches.
Kevin

[Jim Donovan]

Hi Quasi,
The thought is that we will load and unload the rig with the forestay. The rule still does not allow adjustment to the forestay while racing. This is a far more cost/wieght effective way of tensioning the rig than other options. The lock off cleat will be below deck with the tail able to reach one of the winches.
Kevin

Kevin didn't mention that for GP26 class racing he will need to remove the adjustment device, which is a fairly simple process.
For non-class racing, he has a better boat.

[quasi-expert]

Hi Quasi,
The thought is that we will load and unload the rig with the forestay. The rule still does not allow adjustment to the forestay while racing. This is a far more cost/wieght effective way of tensioning the rig than other options. The lock off cleat will be below deck with the tail able to reach one of the winches.
Kevin

Kevin didn't mention that for GP26 class racing he will need to remove the adjustment device, which is a fairly simple process.
For non-class racing, he has a better boat.

I guess you will be using a deck stepped mast then? I can imagine that this setup works somehow like a mast jack on rig with swept spreaders.
On the other hand too much forestay tension will straighten the mast so you will have to losen the forestay when the wind picks up and start pulling on the backstay? seems risky to me to do that especially upwind.

How do you plan to remove the adjustement device? simply remove the line an put in a loop/lashing or what's the plan? turnbuckle doesn't seem to be possible.

[Jim Donovan]

TP52s have adjustable forestays on a swept spreader rig which works pretty well compared to a rig with a fixed forestay and runners.

Kevin's mast is stepped below-deck.
Forestay tension pulls against the swept uppers, which will restrain the forward movement of the mast. Eventually the increasing forestay tension adds compression in the tube which will tend to increase mast bend - this is of course dependant on lower shroud tuning. The rig bend can also be controlled by the adjustable backstay.


All Kevin needs to do to "fix" the forestay is to undo the shackles on the adjuster purchase blocks and lash the forestay strop to the fixed eye below deck.
He could even stick a turnbuckle in-line if he wants an "old-school" method of adjusting the forestay length.

[Kevin Farrar]

Topside and deck fairing is nearly finished. We should be spraying primer before to long. The deck mold needs to clear out so we can roll the hull over - we think it has a new home to go to.
Kevin

Attached Files

•  Cockpit.JPG   125.87K   104 downloads
•  TowRail.JPG   74.99K   98 downloads

[timber]

Kevin,

Beautiful job. I send great amounts of respect.
T

[Heriberto]

Wow Kevin,

Obviously a minimum amount of fairing required. Great to see it coming together as a boat!

[Kevin Farrar]

Wax on wax off.
For a brief moment the topsides had a couple of coats of 545 on them. Most of it has already been sanded off. We will spray them again when the deck is shot. You can see that the forward hatch is layed in place. The spraying will happen when the hatch openning is done being faired.

Attached Files

•  003.JPG   646.55K   76 downloads

[StayinStrewn]

Looking good...I'm wondering how the boat is going to come out of that 'mold' or whatever it's sitting in.

[Kevin Farrar]

We are starting to think of ways to roller her over.
Kevin

Attached Files

•  001.JPG   652.88K   62 downloads

[Mike in CT]

We are starting to think of ways to roller her over.
Kevin

Hi Kevin,

Is there a slot that goes through the hull where the keel is or is that sealed up? That is the point I used to roll my boat over.

Attached Files

•  IMG_20110409_113558.jpg   50.87K   94 downloads
•  IMG_20110409_113614.jpg   63.33K   102 downloads

[mustang__1]

man im sorry i still havent made it down there to help out with this - really sweet project and its amazing to follow in the thread. when i have a weekend off i'[ll try to come down (said that before i know) before she;'s finished up..

[Heriberto]

You must be considering the keel options about now....

[Jim Donovan]

Jim -

I never said Kevin was taking a long time to build the boat or questioned his build quality.

I was replying to StayinStrewn that I didn't think the boat would be in the water racing next year with the list of items still not built or sourced.

Yes - I know Kevin is a sailmaker. Yes - I have met kevin before. Yes - Kevin is only working part time along with the two retired engineers from Electric Boat who are working on the boat

Speaking of how long it takes to build a boat, how is your 20ft coming? Done yet? :-)

Please don't put words in my mouth Jim :-)

Kevin - Keep up the good work!

How are the Russian GP-26 boats being built so quickly? A design that doesn't keep changing? Lower quality? Full time workers?

Both Windseeker and I interpreted your comment "I don't think you will see Farrar's boat on the water for another 3-4 yrs....", as a fairly plain way of saying Kevin's taking a really long time to build his boat.


Even with help, building a boat in your free time takes a lot of time.

My boat project has taken second place to a much bigger and more important project, so it has to wait . . .

Attached Files

•  T4 Hull Mold 10 Oct 2011 A.jpg   424.88K   96 downloads

[Kevin Farrar]

Believe it or not, we have not been letting to much grass grow around here. Here are a few shots since the last post.

Attached Files

•  010.JPG   77.89K   61 downloads
•  011.JPG   76.73K   74 downloads
•  012.JPG   135.51K   74 downloads
•  013.JPG   104.06K   86 downloads
•  014.JPG   71.78K   78 downloads
•  015.JPG   86.71K   87 downloads
•  018.JPG   89.13K   95 downloads
•  019.JPG   104.38K   84 downloads

[Kevin Farrar]

This afternoon we took another step forward. With the strings shaved off its amazingly fair. Tomorrow we will start knocking the epoxy off the foam joins. The strong back and hull mold has moved to it's new home and the deck mold will follow soon.
Kevin

Attached Files

•  036.JPG   80.87K   85 downloads
•  037.JPG   109.34K   107 downloads
•  038.JPG   114.12K   105 downloads
•  039.JPG   103.06K   97 downloads
•  041.JPG   78.64K   101 downloads
•  043.JPG   68.19K   88 downloads

[timber]

Very nice, Kevin.

[Savage 17]

Looking good Kevin!!!! Keep up the good work

[Winchgrinder69]

Tis a thing of beauty , and a joy to behold......a glance at a boat that will change the perception of sport boats...it even has 4 ( count them ) berths ! Lots of cockpit area, and an amazing polar chart ! Winchgrinder69

[Jim Donovan]

Thanks for posting some photos to let us all know what you've been up to.
Looks like the roll over went w/o any issues - boat looks really good

[Ryley]

Kevin, when you say the molds went to their 'new home,' does that mean there's another build pending?

[Prova]

Congrats Kevin! You enlarged your shop! Brilliant Idea!

[StayinStrewn]

what are next steps?

[Heriberto]

That's awesome Kevin!

[psyklik]

This afternoon we took another step forward. With the strings shaved off its amazingly fair. Tomorrow we will start knocking the epoxy off the foam joins. The strong back and hull mold has moved to it's new home and the deck mold will follow soon.
Kevin

Looking good Kevin. Will stop by for a look soon.
~psyklik

[Kevin Farrar]

With the exception of knocking the sharp edges off the chines, so the glass will bend around, the fairing of the bottom (pre-glass) is done. Earlier today I cut long strips of a dacron material we sometimes use at the loft on the Gerber xy plotter/cutter. Tonight I started laying these strips out along the hull surface which began the patterning for the e-glass cloth layout of the hull bottom. Once the patterning is complete the unidirectional cloth will be cut to these patterns. We have already laminated the keel and rudder reinforcement. A fresh shipment of vacuum bagging supplies is due in tomorrow and with luck the lamination with be done on Sunday.
Kevin

[williwaw]

I maybe late in this thread but is your boat the same design as the one in Turkey?

[Ryley]

I maybe late in this thread but is your boat the same design as the one in Turkey?

yes. Kevin started his hull first. It's an impressive build.

[Slappy]

Looking good Kevin, keep up the good work.

[Ryley]

I'm sure Kevin will be along eventually with pictures and his own update, but yesterday saw some amazing progress on the hull, with a cast of thousands getting the bottom skins laminated and bagged. I got there around 10, and the bag was on and working its magic by around 4:30. Not bad, considering the layup. It was great to meet so many of the players in this build - Kevin's got a good, knowledgeable crew and I'm just glad I could learn a thing or two. The bag for the bottom was a pretty impressive piece of engineering in its own right.

I wonder who's going to win the "hull weight" pool...

[Kevin Farrar]

It's a boat. As mentioned in the post above yesterday was the culmination of a very busy week. Making patterns, cutting glass and bag preparation -- just a ton of work. The tedious work of patterning each piece was well worth the effort because the lay-up went smoothly and when I took the bag off the hull this morning it was really close to prefect.
I greatly appreciate the help of the friends who made it possible. Thank you Peter, Ed, Walter, Jon, Stu, Charlie, Lisa, Ron, Lance, Brian and Linda who brought the beer.
Kevin

Attached Files

•  th_024.jpg   5.35K   120 downloads
•  th_029.jpg   4K   115 downloads
•  th_031.jpg   2.99K   72 downloads
•  th_033.jpg   3.46K   66 downloads
•  th_034.jpg   4.28K   65 downloads
•  th_035.jpg   3.78K   46 downloads
•  th_036.jpg   3.16K   26 downloads
•  th_039.jpg   3.35K   34 downloads

[Kevin Farrar]

a real image

Attached Files

•  029.JPG   706.2K   118 downloads

[Ryley]

a real image

We need a full-size "after" shot too - glad it looks as good unbagged as we hoped it would!

[Kevin Farrar]

and another

and another

Attached Files

•  033.JPG   743.38K   93 downloads
•  034.JPG   812.34K   98 downloads

[Kevin Farrar]

still more

Attached Files

•  036.JPG   790.42K   29 downloads

[Kevin Farrar]

This morning after removing the bag and peel ply. Tomorrow I will wrap cloth around the lower portion of the stem then cover the hull with micro-balloons.
Kevin

Attached Files

•  039.JPG   645.08K   61 downloads

[Kevin Farrar]

Shortly after the beer began to flow.

Attached Files

•  035.JPG   802.29K   40 downloads

[Kevin Farrar]

How could I have forgotten our mixologist Tom. Tom mixed the countless pails of resin while reminding us all not to make the laminate to wet. He also kept the running total resin usage weight.
Kevin

Attached Files

•  028.JPG   788.32K   27 downloads

[Jim Donovan]

This morning after removing the bag and peel ply. Tomorrow I will wrap cloth around the lower portion of the stem then cover the hull with micro-balloons.
Kevin

Looks good Kevin!

Pretty soon you'll be this: