NOT 1,000 square feet

Some of you were pretty surprised we got the shop emptied and turned over that quickly. The bad news is “all that stuff gotta go somewhere!” Ugh, don’t look around our small lot at home for a while please. We still have to finish making boat parts, mostly finish sanding, priming and painting. Here’s the new paint shed (code name for an old bug tent now on the back patio under our messy big trees)

The big work table and the large power tools get half the garage (miraculously the car is in fact parking inside now). That’s half the DeWitt Dinghy in the top of the frame – fun little 8′ solo boat!

And all the supplies and small tools go in the 8×6′ tin shed, which got a massive shelving system added on July 3. Still shoehorning stuff in.  

Back at Charlie’s dock this afternoon we removed the stern tower and fished 8 cables through. Anyone building something like this, please note to lay in messenger lines BEFORE sealing up a clamshell design, and make continuous internal conduits with gentle exit bends. My sporty exterior look required much contortion with wire fish tapes and bent fingers. Jim is down from Oregon right now and brought all his carpentry skills to bear on this one. The wired tower slide home and the guys bolted down the feet from the aft cabin while I stood out on the swim platform relaxing with a cigarette (just kidding Mom) Tomorrow is supply plumbing (drains and tankage are done), and finishing the reefing system before hopefully a full daysail on Sunday.  Perhaps we’ll get most of the tower electronics installed too. 


Enjoy the weekend!

Much to their surpriseĀ 

The shop neighbors just laughed and shook their heads as they closed up their businesses Friday afternoon for the holiday weekend… The boatbuilder had said this mess would disappear by the time they reopened!

 
Most of the tools were home already before that photo, but as usual we were trying to “multitask”; still building parts until the last possible moment. We were packing to the tune of the vacuum pump as this table full of cabinet doors and companionway boards came to life. 

No fireworks this year as the Fourth gave us new doors and a disgraceful amount of landfill waste

We will live ‘greenly’ on Ravenswing, but the construction left a debris trail that was a bit unnerving at the dumps this morning. It was pretty weird handling every scrap with all their memories of missteps, fixes and clever accomplishments over the years. But also a HUGE relief when the landlord snapped this photo with the keys in her hand and the Carters no longer the Piner Industrial Center boatbuilders!

Big thanks to Michael the woodworker for all the tool loaning and advice over the years. To Mark for wrenches and the forklift in a pinch. To David for painting advice and labor leads. To Marcus for Giants fanaticism and damn funny humor. The Piner guys get a McCovey Cove day Aug20 on the boat; we’ll be the ones on your TV with the huge World Series Champs flag that Marcus got from the steps of City Hall celebration in 2014.

Hey Griff, pool-cover Nevin traded his new portable air compressor for our old huge one, so I didn’t have to move the BigPig out of the shop and we have a nice beefy 2hp compressor in the garage now :)

We could not have finished the boat these past five years without this place. A note to current or contemplating builders: it’s easy to underestimate the costs of a rented or borrowed shop in a build budget. Mostly because IT IS going to take longer than any of us plan, and that rent check has to keep being written. For us, the extra 12 months rent devoured our electronics savings account, so Ravenswing launched without the Tesla-like lithium batteries, light weight 600 watt solar array or desired Furuno comms/nav goodies. But overall, choosing a workspace one mile from home was the best thing we did for this whole project. The proximity made getting to the boat work an easy thing, so more got done any given week. Do what you can to avoid commuting to your hobby job! Finally, go big. 48×24′ was really too small for this boat. If ever again, the shop would have to be large enough for the tri or cat to stay in its fully assembled wide condition. 

So now the boat to-do list gets tackled  from the dock. First up is solving motor cavitation (severe power loss due to poor water flow or air bubble entrapment). The protection leg in front of the motor is too long. Not sure how much, but it sits 3″ below the waterline and cutting 6″ is the common sense move. Pre-cut here:


Half a foot later

Then we took the offcut to Charlie’s table saw and salvaged the bottom cap, clean-up sanded the cap and the motor mount, and prepped a batch of peanut butter thick epoxy/cabosil paste. Loaded the kayak to continue the 6pm surgical reconstruction…

And plastered that cap up where it (hopefully) belongs

That seam will get cleaned up and covered with a bit of fiberglass next week after this current business trip. If I’m lucky, our boat dock host will have tackled some lazy Jack improvements this weekend :)

We’ll get her sailing for real very soon. 

First sunset

F36 #5 became a trimaran for the first time today. Her assembly team struggled mightily on Sunday to bolt the beams in to their float sleeves and form the complete boat, but we ended the day with the starboard beams flanges 3″ above the float deck. Frustrating for everyone going home, and pretty much a freak out for the builder who crawled in to the cabin solo and quietly tried to figure out what went wrong. (Remember this had been put together in the shop two years ago so it was supposed to be easy this time). A fresh mind at 6am realized I must have added fairing and paint thickness to sleeves and beam ends that made the difference. Before anyone else returned to the site Monday morning, the float hull was pryed loose from its stuck position (thank you for that lesson Carlos) and lowered near the ground to give access to the sleeves / pockets. When the gang arrived we ground back all the added materials and greased the heck out of the parts. It was still a very tight fit but an hour of fiddling got the float properly mated to the beam. And the boat became a tri.

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Huge thanks in the journey to water to everyone who made their ways to Napa. Carlos, Don, Rick, Dean, Goose – you guys are so kind with your time and energy. Charlie and Jim, what can I say, except 3 f27 Amigos wanting a shower and fridge in our fboat, right? Carters&Joe, although I’ve been a bit crabby in spots I am loving doing this work with you. Thanks for devoting this time to finishing the long project that has cut out many other things.

So, we’ll use Tuesday to test the motor, install the nets and daggerboard and finish up some hardware and safety items. We’re planning on the Weds 10:30am high tide to launch. (Need the high water at this ramp), and stepping the mast hopefully Friday. Call or email for more details as you wish.

It’s a little stunning to believe we actually made this:

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Well in to the evening

Friday was a long one. Here’s Jeanne doing a heroic cleanup, including going after four years of dust under vee-berth

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Beams loaded and rolling to Napa on little trailer

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CrazyCrane got the mast off the trailer – Charlie is seriously all-in on creative boat solves!

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Mast delivery to Napa Valley Marina

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Assembly site a mile from the marina

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But the best was rolling the boat outside in the eve. Wow does it glisten in the sunshine and make this family proud!

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So we were feeling good at 7pm, and then came the daggerboard fitting. Remember this has never happened because it was too tall inside the shop. … Damn, the trunk is slightly shorter at the top and bottom four inches based on how Howard did his glassing work (hull builder) and we didn’t talk about that. I built the dagger to exact plans. It sticks and wouldn’t clear the foil shape slot thru the hull :(
9pm emergency surgery to cut 5/8″ off the trailing edge. Michael Metela next door is the second hero of the day (Nameless Tractor Guy was first )

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The boys hauled it back on deck, and it slid home just fine. That left the boat builder a late night of glassing – vac bagging. At least it made it easy to roll in to the rack at 1:45am as the night watchman.

Ok, 7am Saturday now and a huge forklift / Gradall comes at 9 to help get the boat on the trailer. Stay tuned.

Inching Forward

We’ve done a good job ignoring the bottom on the hull for years now. It helped to store lots of supplies under there and hide the work needed. But Thursday evening was time for a big cleanup and rearrange, centering the boat in the shop with good clearance all around. Time to drop to the ground with a bucket of epoxy filling putty and get to that bottom job.

This is looking up at the stern, about half way thru applying the final primary skim coat. The pencil line is hand drawing the bottom paint waterline at the same 35″ above the floor all the way around. We’re going to apply bottom paint 4″ above the planned waterline, especially since I don’t want to have to pull the boat for re painting if it rides low at the initial launch.

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Inching along the hull, carefully filling all little nicks, gaps, hollows and pinholes from construction and earlier prelim fairing a few years ago…

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And 8 hours later, finally getting to the pointy end!

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Next up is spray painting a “guide coat” to look for any more low spots. That’ll take some photos to explain.
But not today; it’s time for a day off and crewing in the Great Pumpkin Race on Drew’s F27. Sail fast!

videos for Cozmo

cos-1Does this guy look like a pro sailor / pro boat-builder or what? Marc Cosbey has prepared a lot of grand prix sailboats for some of the biggest races in the world (like his America’s Cup mugshot above). Last winter the re-launch of the first big Gunboat, in timeĀ for the Transpac, had his attention. And if I don’t screw this up, we might get his skills roped in to Awgrip-spray the F36 this fall. So before Coz says yes, he wants to see the project so far. Since he lives 4 hours away in the beautiful Sierras, here’s some video to start the conversation…

4 crappy iphone movies for you, Coz; the main hull, the deck, the interior (nothing needed in there) and a quick overview of the workshop. The two float hulls, the mast and the 4 beams are already finished in Interlux Perfection (roll & tip) and off at a storage yard.

 

shop video

hull video

deck video

interior video

Kids, don’t try THIS at home!

You gotta love friends with forklifts. Thank you Mark at the Airless Repair Center next door! He lifted two boat hulls for us today. Spotters were Charlie and Dean forward, with Colin and Griffin managing the sterns. Mrs. Carter the Co-owner did a great job with the camera. Here goes:

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The smartest thing we did today was decide before lifting that the forklift would be stationary. No nudging the lifted boat and causing any sway; the truck and trailer had to line up under the boat. That was easy with such a long wheelbase.
Hours of good prep placing the posts on the trailer and figuring out Rick’s lifting straps led to only a couple of minutes needed for each lift. Watch the first one here:

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After the video we pulled the truck forward, moved the second hull to the cement pad and the forklift to the other side. All good.

Notice that first the floats were truck-strapped to their trollies. Then the lifting straps went around the hulls only, and upon lifting the hulls brought their strapped trollies with them. Lifting straps around only the hulls created a much safer pull with no wracking stresses on the wood trollies.

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And we’re down. The four truck straps then got moved to travel around the trailer frame, and more strapping to tie the two floats together against any side to side forces.

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No drama today, but kind of stressful for the boat builder :). It was a big relief to take this shot before heading to dinner:

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It’s going to be a big boat all put together.

And being an opportunist, I finagled the big crew for 20 more minutes to get the mast down from the rafters to ground level. For those of you who’ve been to the shop, you know what a shoehorn that was! Yes, the rotator pin just fits inside the small entry door with the masthead jammed in to the far diagonal corner. Phew. Mast modifications start in the morning. Stay tuned.