The drawings: I bought them from Dudley Dix on dixdesign.com .I ordered the complete package including the full scale drawings. I can tell you now that that saves a lot of time. I can recommend that to everyone.
Buying the wood. 50 sheets of marine graded okoume multiplex!!! That's a lot of wood. I used the guideline that Dix has standing on his site. We will see if it is enough or to much. I bought some sheets in an extra large size 310X150 so the complete bulkhead fits out of one sheet.
Putting the drawing on the wood. I have to say that once you get the hang of it, it goes pretty fast. I did it with a small pin and a small metal wheel. I used the pin to make straight lines from one point to the next one. And I used the wheel for the round corners.
Epoxy. If you are making a boat according to the woodcore methode, at a certain point you will need to buy some epoxy. Poly-Service from Nieuwerkerk aan de IJssel in Holland . Those guy's know everything that you need to know about epoxy, polyester, special paints, glass fibber and so on. I first bought the primer and the thick epoxy that I will be needing for the fillets. I bought 30 kilo thick epoxy I know now that it is not enough. The very thin epoxy primer is used to get a better bounding with the wooden sheet's.
The epoxy corner. Very important in the whole story. The temperature. The mixing rate. The moister and not to forget the hand gloves.
Sawing, sawing, sawing. After I put some drawings on the sheets it's time for the sawing. I can tell you that it never fit's on a sheet of plywood. U will have a lot of waste. I hope that I can use it somewhere else, and other wise it's pity.
Milling. I made the slots in the bulkheads with a hand milling machine. I found out that it's more handy to first glue the whole bulkhead together, and then mill it. But that is after I did it the other way first.
Finishing. After I sawed and milled everything it was time to finish it. that means take all the sharp edges off. This went very well with a mini belt sander. After that I put the bulkhead's in the primer epoxy, so that everything is standing ready.
The rudder. Ok. It is a bit of work but then you have something. A garage full with dust to be precise. I made them from a sheet of plywood 30 mm thick. A electric planer did the rugged bit, and a sander the rest.
Till here I did everything in my garage. Most of the time it was still freezing outside.
The tent. I think that my garage isn't very small, but for a mini 650 I have to have something else. After a bit of thinking I decided that I will make a foil glasshouse to build my boat in. On the internet I found a number of arches which have been used as a cage to hold some ostriches. These arches were made from a slightly bigger diameter pipe then they normally use for plastic glasshouses. This has the advantage that they are already quite stable itself. I did put a piece of pipe in concrete over with the arch is going.
The plastic. I have bought myself a roll of plastic foil from 6X50 meters. This foil is 0,2 mm thick. I though that I could put two sheets of this foil together with two site adhesive tape. To make one sheet of 10X12 meter. But that did not work out the way that I wanted it. Most tapes are not UV. resistant. After four days the tape did not hold anymore. So the whole bit came apart and I had to start all over again.
Hot glue. I found out that the only way that you can put two sheets of plastic together is by welding the two together. So I bought myself a hot-gluepistol. I thought if you can weld it than that should also work. And after a testing period of about 3 months I can tell you now, it works.
The bulkhead frame. I made it from an old garden fence. I put it, as they advised me, solid to the ground, so that it can not get any room to not become in line.
With a laser level. I put a line on every bulkhead pole so that everything is standing straight. And with a simple piece of rope I put all the bulkheads in the middle.
The keel. The wooden parts where all standing ready, and could all be mounted. Now the bulkheads and the keel are mounted you can almost see how big everything is becoming.
The stingers. I have made the stingers out of 18mm plywood. I did not see any advantage for cedar. Later on I found out that cedar is much lighter than plywood, oh well.
Putting the stingers in place. I first measured all the stingers in place. After that I glued them all in place. When I finished that the whole thing was already that stable that I could walk on it. And that means something.
The Tangents. That is the bar that is on the place were the hull and the deck are coming together. I made those also out of plywood. 22mm that is. It seams that you have to make this one perfect in place. The angle changes from about 40° to 80° .
The hull skin. There where no drawings for that. And I did not need them either. It is just a matter of putting the sheet to the frame and putting some lines on it so that I can see were to saw and were I have to put the screws and the clamps. I milled the edges a little so that they form a nice closed layer later on.
Radius chine. That is the part in between the bottom and the side of the hull. This is the part with the most rounding in it. There is no other way then to do this with two thin sheets of plywood. And even then I have to use strips of it. Because it is bending in two directions. It is as with a lot of things when you are building a boat for the first time. Once you get the hang of it, it is no problemo.
Howe to put two thin sheet's of plywood together. Just put a lot of screws in. And pull the whole bit with epoxy in between together. I looked at the site of a school in America where they are also building a mini. And saw that they where doing it exactly the same way. I needed about 2000 screws. But what the heck, I will take them out anyway, and put some epoxy in the hole's later on.
The hull is ready. Now that is a nice marker. Now there is laying a boat in my backyard. Isn't that something.
Safety before everything. Now it is time for a lot of sanding. So I bought myself a nice dust and gas filter. I will be needing the gas filter later on.
The epoxy coating. I have bought the rest of the epoxy coating that I will be needing, and also the glass fibers, the rollers, the degassing rollers, a lot of cans, mixing sticks, sanding paper, carbon fiber belt, pansercoat, glass bubbles, etc, etc. You will see it all coming by later on.
Sanding, sanding and sanding. It was a lot of work to sand everything away. The epoxy is very hard and maybe I should have cleaned it better. But that is not so easy. When I pulled the two thin sheets together the epoxy kept coming out as long as it wasn't cured.
30°C. It can be very warm in a glasshouse when the sun is bright and shiny.
First layer epoxy primer. It is looking good already. I had a little epoxy left over so I put the first layer of epoxy on the rudder and the dagger board.
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