posted
Nov 2006

 

2008 Solo Transpac and 2009 Single Handed Trans Atlantic racer.

Report 1
Report 2

Superceded by Solitarry Report 3 : Solitarry

 

 

 Construction has begun. The ww hull is built from flat sheets, with carbon on one face. The sheets are formed into truncated cones, then they are placed inside frames to force them into the desired shape, and the internal laminate applied. They are then joined amidships. The ends have a bulkhead filleted on, then polystyrene is glued on and shaped.

 

 The Polycore cut to shape, ready for the carbon. Note the piece of plastic tape over the extended edge. This is for the gluing flange. Next time I will put some bog in the panel joins to facilitate an even bend.

 

 After the carbon has cured, I hot melt glued a piece of 4 x 2/100x200 timber on each edge and bent it to shape using ratchet straps, then glued the join. This should have had some bog in the core and maybe more support so that it was flat rather than peaked at the small end.

 

 Once the join cures, the hull half is pushed into female frames to give it the required shape. They don't require much force, and as can be seen, the amount of curvature that can be achieved is quite high. I should not have cut out the pieces for the hatch and bunk, as they meant the frame was not right at the end of the cone. Consequently, the hull flared a little. If the frame was right on the end, it would have done the opposite, meaning less fairing of the join.

 

 View inside prior to carbon. Laminating this was not as easy as doing it on the bench, but the ability to rotate it meant all work was downhand, so it was not too much of a chore.
The two halves joined together, with the ply ends on and cut outs for the hatch and bunk. Weight 25 kgs. Time, a couple of weeks, but this included learning some lessons, some mistakes and a fair bit of sitting and thinking. Actual working time was about 8 hours. 1 hour to cut the frames, 1 to cut the core and carbon, 1 to laminate the exteriors, 1 to bend and glue each edge, 1.5 each for the interior, 1 to join them together and fillet on the ply bulkheads.

 

With a little cutting and shutting, it would be possible to induce some sheer curve. However, I don't mind the straight and I may be putting some curved solar panels on the hulls, so any compound curvature would be bad news.

The bond between the epoxy and the Polycore is very strong. Far stronger than to foam or any strip plank material. It soaks up about 200 gsm of resin, about the same as H80 foam. There are a few things I'd do differently if foam was used, but so far I am very happy with the Polycore as a building material.

Next is the polystyrene ends, bogging and carbon on the join, then the beams and the bunk. Then there is 'just' the lee hull, rudder and the rig to build.

Rob Denney


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