It’s been another crazy week on The Discoverer Project as we have moved ahead with sub-floor fabrication in the cockpit. Craig and Jack made a heck of a mess grinding and cutting out the fuel tanks (see last post) so the first step was to clean up the evergrowing mess of fiberglass dust and wood shavings.
Charlie has already cut replacement rails for the holes in the floor and now begins the process of glassing them into place. The red clay-like material in the foreground is actually millions of microballoons that (when mixed with hot fiberglass resin) turn into a putty that can fill gaps much better than fiberglass alone.
Charlie laid his first round of fiberglass tape around the two large central openings, then cut six pieces of marine plywood that will be encapsulated in glass and eventually become the new floor for the Discoverer
That night disaster struck as a fog bank rolled through Jacksonville and wrecked havoc on the fiberglass resin setting up. When Charlie showed up to check his test section of fiberglass the whole piece detached.
There is no avoiding moisture-related setbacks when you are working on a boat outside in Florida. Fortunately we are getting to the time of year when the temperature and the humidity are on the decline and hopefully we can get through all of the fiberglass and paint work before the summer starts again in February.
On his second attempt Charlie achieved adhesion and could move on with enclosing the forward deck holes. Since the forthcoming fuel tanks are significantly smaller than the old ones we will fill this dead space with marine foam; you can never have too much foam in a hull.
The next trick up Charlie’s sleeve is to build a fiberglass arch intended to tie the fighting chair directly into the stringers. On the Wanderer we struggled with the best way to secure the fighting chair; not only must it withstand the abuse of reeling in 600+lbs. Marlins, any fighting chair gets grabbed alot by anglers and crew seeking balance. Sometimes the weight of three people are yanking on this thing so through-bolting it to the fiberglass floor is just not strong enough for us.
On that boat the solution was to screw a 3/4 stainless steel plate into the stringers horizontally. It did the trick strength-wise but weighs alot and is not very elegant. Charlie has proposed a dynamite solution with which we are quite happy.
This arch will receive another coat of glass that will fully secure it to the stringers, and once it does we will have a perfect spot to secure the fighting chair on the Discoverer. Speaking of fighting chairs, check out the rebirthed Wanderer chair:
First Mate Alex really outdid himself on this project. I can’t wait to see this baby in action come November 1!
Next up for Charlie is finishing the covering decks for the fuel tanks and running final surface coats of fiberglass to the cockpit floor and the front nose deck.
Meanwhile we are waiting for our fuel tanks to arrive and getting our ducks in a row for the upcoming month of hanging the transom deck and painting the boat. Stay tuned for more fun as it happens!