Soft spot on the roof - Part 3

Amazing how big the boat looks like in this
picture!

Here we are again! In a few days from now, we will glue the corecell to the fiberglass using gelmat (a mix of polyesther resin and fiberglass strand). To make sure it sticks firmly, the surface needs to be perfectly clean. So today’s goal is to sand the remaining balsa and then clean the fiberglass with acetone.

First off, let’s be honest here : the fiberglass cutting created enough dust that our faces and necks (and hands, and backs) (and whatever you can think of) were itching like crazy. It took me 8 times washing my face before I « kinda start feeling » back to normal again. We bought a wonderful white one-piece working kit with a hood. Sam looks like he’s ready to star in a Sci-fi B movie, but we are really counting on that to prevent the dust from entering everywhere.

Using the Ridgid Job Max oscillating tool, Sam removed the thin layer of plywood that was stocked to the fiberglass. Worked great!  You really want that kind of tool if you star such project!

Using the same tool, he started the sanding job. Terrible! The thing was vibrating like crazy  but almost nothing was happening on the head. Sam went to buy another tool (thank you Fein!) that worked perfectly.   If any of you is wondering if the hype behind the Fein is justified, Sam can now convince you anytime!

Next step :  we did put on masks for toxic vapors. Sam applied Acetone on a cloth and washed the fiberglass. The few things still stocked to the roof did melt easily. (smell is terrible though) We waited that it dry outside. (smelt even outside).

Cutting the corecell

Finally, there was enough time to cut the corecell. We  divided into 9 pieces. Why 9? Well first because the shape of our repair is quite artsy. Second because the size of the repair is too big for 1 big piece of core cell. It needs to follow the bending roof and the core cell is too rigid.

Good work for today! We are a bit late on the blog ; i just realized the heater was on and that I had my winter coat on that day. Next time might be a bit more spring-ish!

-cass

Using tape to keep the pieces in place

The final assembly.  Triangles will help align them back perfectly while gluing

Time spent : 3.5 hours
Purchases:

• Oscilliating tool (Fein): 200$
• Sanding paper : 5$

Total time spent so far : 10 hours

Total cost so far : 415$