Hardtop Project Part 3

So for most of the week Paul and his guys have been working full days building the mold for the bottom side of the hardtop, the side you will see. I think it is almost done. The mold is made up of multiple layers of 1/2" MDF. Very labour intensive. It has been apart numerous times before final lamination and gluing (West System Epoxy). Every panel is labeled, dowel pins ensue perfect alignment
The last day and a half have been spent fairing, sanding and sealing.

Sanding and sealing the mold. Everything has to be perfect. Not easy to see here but all edges are radiused, channels are tapered. If not done correctly the part will not release properly from the mold, will have tear outs and will require a lot of after mold repair not only time consuming but it would add weight.  If you are wondering why I am obsessed with weight, I like it down low, not up high. 

Below is the top of the hard top, (see part 2) just being "unbagged". This structure weighed in at 70lbs!

The beam of light across the panel is pure Trini 8am sunlight!

Hardtop Project Part 2

The lamination begins! Starting with a release layer wetted out with epoxy, then a layer of woven bidirectional carbon also wetted out, topped with 1/2 foam coring. On top of the foam coring both bidirectional and unidirectional carbon all wetted out with West System epoxy by rollers.



Mold is waxed then a release layer is laid and wetted out with epoxy

The bottom bidirectional carbon has been laid and wetted out. On top of that layer you can see the 1/2" foam coring. The unidirectional is laid in a strategic pattern to add stiffness. The first few pieces of bidirectional are being laid on top, all wetted out as the process moves forward.

Final few pieces of bidirectional carbon fiber being laid.

All the carbon is now laid down and wetted out with rollers.

Laying down a perforated release layer, This film has tiny pin holes to allow the vacuum to work effectively.

Perforated film in place. Laying down the bleed layer begins.

 Bleed layer laid down and being trimmed.

All bagged and under vacuum, the vacuum draws out any air, excess epoxy and compresses the carbon, Light and strong!

Hardtop Project, Part 1

I am back at Peake Yacht Services in Trinidad and Tobago. Sylvianne stayed behind while I am doing boat work and watching our hard top come together. I had previously mentioned the project to Greg Downes, the service manager at Peake and he said, "I have the man for you, let me put you two together". Paul Ammon, (aka "Englishman") as well as an accomplished sailor, is a builder of racing sailboats in both glass and carbon fiber. Paul and I discussed our ideas and he added some of his own then went to work to figure out how best to design and build the top. We had three main criteria.

1. The top had to have the same look as the rest of the boat, once complete it needs to look like it was part of the boat as delivered from the factory, not an "Add On".
2. The top had to able to support a person but at the same time be as light as possible.
3. The top needed to be able to accomodate our planned solar upgrade.

Criteria number one, the look.

I had a concept in my mind of taking the look of the cockpit ceiling with its 3 degree radius and beams and carrying that look to the flybridge hardtop. I originally envisioned the top would be supported by a stainless steel frame. Greg Downes had suggested maybe glass, he had seen a top that Paul had built for a catamaran done that way. Hmmmm......maybe, but I still could not grasp the concept, sounded difficult and complicated. In steps Paul, he has some pictures of previous projects and we chat. Paul comes to the boat and does a "mock" up. Ah now I get it!

Criteria number two, strong and light.

It is decided that carbon fiber combination box beam/foam core construction is the way to go. Paul assures me that if he designs it correctly it will be very light and very strong. He will build a mold for the underside with all the beams hollow and a larger center hollow cross beam which will have access panels to run the solar panel wiring, add lighting etc. This larger cross beam will also be where the support legs will attach. For the top he will use an existing mold and laminate carbon fiber to a 1/2' foam core, vacuum bagged.

Criteria number 3, solar upgrade.

This was easier, Paul increased my original design slightly to both improve esthetics and give us a bit more room for panels. We plan to use the same type of Solara panels as we used on the pilot house. Very light flexible "walk on" panels with a slip resistance textured surface.

Yes, We Actually Did Some Cruising!

We had a really good cruising season, Carriacou, The Grenadines and a 6 week Circumnavigation of Martinique. If you like adventure the East coast of Martinique is wonderful.

Petite St. Vincent


                                                                                              Marigot Bay St. Lucia

Stabilizer Rebuild

The rod end bearings were getting sloppy, I decide to do the work myself.  It made good sense as we were replacing the washer dryer and that made it easier to cut a nice big hole for access under where the washer dryer would normally be. Since we were in there anyway and we were at the hours recommended we change the cylinders, trunnion and rod end bearings.

 

 Access??? Hmmm not really possible to work on this actuator from the provided shower access.

 So, remove your Washer/Dryer and cut a big opening.

Thanks to Daryl at TRAC for helping walk me through this via WhatsApp.

Solar is the Way

Well just to update you on the Solar on Sylken Sea, we anchor out or take moorings whenever possible, we boat mostly "off grid". After 10 seasons we have 4800 hrs on the Generator, so before solar we put 400-500 hrs a season on the Genny. By converting many appliances, lighting, TV/Entertainment Centre, water maker, refrigeration etc to 12V, now with our current 1200 W of solar last season we put 56 hrs on the Genny! The only time we run it is to heat water and do laundry. Plan to bump it up to 1800W and ad some water heating capability.

More Solar

We also removed everything from the top of the Pilot House, moved the Name Boards, trying to reduce as much as possible the "shadows" on the new Solara Panels. Kirby our painter to a great job customizing the Non Skid pattern to outline the panels. I think it is very slick looking installation. The Solara panels are textured and designed to be "walk on" panels, no wires visible, light weight, no mounting brackets etc.

Shiva is a master with sealant, we just glued the panels in place.

Very good skill sets in Trinidad, these guys will build you a complete boat from scratch, just bring them your plans.

We Get a Paint Job!

At the same time as we had the hatch removed we had 90% of the topsides from the caprail on upwards painted, all the non-skid redone. It took more than 6 weeks 2-3 guys to do the prep and only a few days to actually apply the final paint. We had all the hardware removed, everything rebedded and all sealant around doors, windows, Here are some images of Sylken sea in "primer".

Hatch be Gone!

I was rather delinquent posting this last year, I'm playing catch up!

We had the boat delivered without the cockpit ladder to the boat deck, we did not think we would use it and it takes up a lot of space. The unused hatch cover on the boat deck was a pain in the behind, always collecting standing water, green slime growing in it. So.....we had it removed and glassed over, looks like it came this way from the factory!  This image shows the underside, epoxy primer ready for paint.

Hello All

We had some really cool stuff done to Sylken Sea in Trinidad, very happy with the results so we are again back at Peake Yacht Services for some more upgrades, this time a carbon fibre "Hard Top", railing modifications, pilot house door painting etc. Heading there tomorrow, promise you more updates.