Thursday, July 17, 2014

Core Sound 15 Centerboard Construction

Below is a video of the process of cutting and gluing up the quarter-sawn strips of wood that make up the centerboard. The finished blank for the centerboard is very stable because we "end for end" every other strip in the board which cancels out the bending or twisting tendencies of any individual strip. The strips are oriented as close to quarter-sawn as possible to reduce the effects of expansion and contraction of the wood.

Ideally this process starts with a straight plain-sawn board with little twist. The boards I used were not as plain sawn as they could have been and so I ended up with some strips that resemble more rift-sawn cuts. One could be more picky with their strips and weed out the rift-sawn ones.

After the blank was glued up it was put on the CNC machine to be shaped. The creation of the part files takes about twice or even 3 times as long as the cutting itself. The entire process took about 6 hours to draft the centerboard in 3 dimensions and create the cutting files. That includes the surfacing and hole drilling and outline cutting. Each of these processes involves a different set of menu options in the software and each produces a separate file. It is not as easy as throwing in your 3d model and out pops a centerboard. Each file has to be referenced correctly to the origin so that all the cutting operations happen in the right spot in relation to all the others. Otherwise the two halves of the board might not match up!

Here is a video of the processes that went into cutting out the centerboard. The obvious advantage to this method is that another centerboard can now be created using these files in a fraction of the time. And all in all, the final product is more accurate that one could hand shape given 6 hours with any hand operated tool.

Friday, July 11, 2014

Core Sound 15 Centerboard Trunk Installation

This week the centerboard trunk was installed in the cockpit and awaits fiberglass taping. I also started on construction of the centerboard which will be the subject of the next video.

Monday, June 30, 2014

Part 6 of the Core Sound 15 build

Had the chance to get more parts cut out for the 15 last week. Here is a video of the progress to date:

Below are some pictures of assembling the B and B waterproof hatches.

The assembled hatch and hatch ring. 

This is a rendered view of the finished hatch.

Here it is seen from below. All edges would be rounded over.

Here we have an exploded view of the hatch lid. 

This is an exploded view of the hatch ring showing all the parts.

And now for the real thing.

 Here is the hatch lid being glued up on a flat table to eliminate the possibility of a twist in the top. The parts were assembled with dabs of hot glue and then filleted. The hardwood beam across the back cannot be hot glued down like the plywood sides. It must be glued down with thickened epoxy. 
Here are the parts for the hatch ring. The sides and back rail are hardwood. They were glued on after the inner corner of the plywood parts were filleted. 

Here the hatch ring parts are dry fitted and hot glued together to hold them in place while being filleted. The hardwood sides are just dry fitted.  

Here is another video from B and B last week of the crew lifting the hard top on to the 45' powercat that is nearing completion at B and B. 

Saturday, June 21, 2014

More Progress on the CS 15 Kit Prototype

Here is part 4 and 5 of CS-15 kit prototype build. Next up will be getting the centerboard trunk installed and working on the cockpit hatches and seat tops.

Tuesday, April 22, 2014

A Little Side Project

While the CS 15 takes shape I had to get moving on another project I promised I would do for my friend Doug (AKA Ridgerunner) who is building the first Core Sound 20 MK3 from a kit. He has lots of pictures of the build on his blog

He will have the boat down at the Cedar Island get together in Florida in a short time and I built the weighted centerboard for the new boat. 

I used Graham's design to create the cut files for the new CB and glued up the wood blank for the board. 

The blank is glued up from laminated quarter-sawn pine about 1" larger than the board on all sides. A large flat table really helps for this part. Double and triple check that the strips end up as flat as possible with no twist. 

The finished blank was too large to run through the planer at the shop. Step one was to use a large surfacing bit in the CNC Machine to take the blank down to its final thickness. Dowel pins on either end of the blank on the center line allowed the blank to be flipped so that both sides could be machined without having to worry about if the blank was aligned properly.
 Step 2 was a roughing pass to remove 90% of the material not needed in the finished shape. A 1/2" end mill was used.
 Shown here are the final seconds of machining the finished surface with a 1/4" ballnose bit. The resulting surface has small ridges that are easily sanded smooth. The machine could make the surface perfectly smooth with no sanding needed but that could take it all night! A little sanding was faster in this case.
 The resulting board after machining and cutting the final profile to free the board from the blank. Pivot and uphaul holes were located perfectly by the machine. Total machining time was about 2 hours.
 It's quite a big board.
The lead weight in the tip of the board was calculated using CAD and the appropriate cut was made with a Japanese saw for minimal curf. This being the first CS 20 MK3 Centerboard the tip will be used to cast the lead tip. In future boards the cut files will be modified to leave off the tip and so a smaller blank will be required.
 The CNC machine sure can make a nice foil!
Pouring lead into an open sand mold. Our sand mold consists of a flask filled with hard packed "green sand" (sand mixed with bentonite clay and water). The wooden plug was used to create the cavity. We also cast a lead tip for a CS 17 MK3 at the same time. If you're interested in sand casting with green sand there is an excellent youtube channel you should visit called MyFordBoy. He has some wonderfully exciting (at least to me) casting and machining videos mainly in aluminum. 

As we are just learning to use green sand we went for an open mold that resulted in parts that needed some clean up afterwards. Our holy grail is to cast an aluminum mold for the lead tips that can be machined to a perfect surface. The aluminum mold could then be used to make hundreds of perfect lead tips without having to pack sand each time. 

Yes we probably should have been wearing masks but it was a particularly well ventilated (windy) day. 

There was more sand texture at the bottom of the pour when the lead was hottest and swirling around the most but overall no major problems with either pour. The sand was very hot after absorbing all the heat from the lead. After casting the green can be reused over and over. The sand is put through a sieve and a little bit of water added back.

 A quick wash brought the lead back to its normal cold feeling temperature.

 Lead is fairly easy to work with normal wood working tools. Be sure to keep your shavings and wear a respirator and gloves. It can be planed with a hand plane if you're prepared to sharpen it afterwards.
 Nice shape! After shaping, the entire tip was "keyed" up with 36 grip sandpaper in a swirling motion to make crossing scratches in the surface. This aids in the mechanical bond to the fiberglass.
Target weight: 17 lb 9 oz. DAMN IT we were off....he said sarcastically.
 With the top of the board clamped to the work table, two hardwood scraps were attached to one side of the board to act as a cradle. Shims were added until the lead would drop in and sit centered and fair with the wood edge. The shims were put down with hot glue so they wouldn't fall off once the fit was perfect.
 Views from the bottom. A screw holds the strips in place.
 Fitting the lead. Once satisfied with the placement, the wood was wet out with un-thickened epoxy. Then a thickend mix of epoxy and cabosil was made to glue the lead to the board.
Once the lead tip was glued on, the CB was moved to the work table and the first side was glassed right away with 10oz fiberglass cloth.

A wide putty knife with thickened epoxy was pulled across the lead/wood joint to fill in any unevenness in the joint prior to laying down the fiberglass.

On the trailing edge a flat stick covered in packing tape was temporarily hot glued to the underside of the board to create a lip. Thickened epoxy was used to fill the lip and the glass was applied over top. This extends the trailing edge about 1/8" with thick epoxy and allows the TE to be shaped to an asymmetric point to reduce vibration. While a 30 degree or less trailing edge is best, an asymmetric shape with one flat side and one side cut at 45 degrees rounded into the rest of the board is very very close to ideal in terms of reducing oscillation or "board humm"

The fiberglass was cut about 2" too big and wrapped around the leading and bottom edges. A hot glue gun was used to "tack" the dry edge of the glass to the opposite side of the board to keep the glass wrapped around the edges. Afterward the hot glue was scraped off with a scraper.

Above: The finished board with a coat of epoxy to fill the weave. The wrapped glass edge was sanded and feathered into the wood before glassing the second side. The second side glass stopped at the center line and the edges were sanded smooth before coating. The lead tip is held on with fiberglass alone no other mechanical fasteners. The board being nearly and inch wide at the tip gives the fiberglass (which has a very high tensile strength) a lot of leverage to resist bending at the tip. 

Monday, March 31, 2014

Another project taking shape

I'll get back to writing up our EC story hopefully soon (after it sinks in some more). But I'm already onto the next project.

I've been commissioned to put together a Core Sound 15 sailboat and have developed the kit for the boat (not previously offered by B and B as a kit) and am using this boat as the prototype for the kit.

I created a 3 part video documenting the assembly of the hull from flat panels to final shape of the 3D Hull. Enjoy

Wednesday, March 19, 2014

That's a Wrap.... Back to the Real World

The EC is a personal journey of exploration mixed with salt, ocean, weeds, mud, bugs and sleep deprivation. One cannot fully describe the feeling of participating in this event. You just have to do it yourself. To learn about yourself, push your limits and find out what your made of. Surely there are few ways to accomplish these goals so effectively in a world of smartphones and facebook. After this years EC I've had an urge to get on the water more, I've had more vivid dreams in general and I like to think I ponder the world in a deeper way. Maybe I've just lost a few hundred more brain cells but it sure feels good! I've also got more boat design ideas swirling around in my head, more than normal anyway.

Mosquito performed better that I could have hoped. Although she has already completed the UFC in 2012 she was loaded down with many pounds of extra gear for the portage and in such a long race pushing a new design to the edge is not advisable (breaking is not fast) she also suffered from a small leak that kept SandyBottom and I bailing all the way around Florida. After collecting dust since our 2012 run Mosquito was given some much needed and deserved love and attention. A new coat of paint and some new graphics thanks to my sailing partner this year Jake and his graphics business Green Room Graphics. The goal this year was to really open the throttle and see what she could do. Mosquito took care of us in all conditions although she does better when you give her enough water to play in (beware Checkpoint #2). I am glad to report that Jake and I found Mosquito to be as fast and powerful as I always imagined she could be.

Here are a few pics of our run in this years EC in the Mosquito Trimaran. Oh yeah and WE TOOK 3rd Place!!! Finishing in 2 days 9 hours and 55 minutes. Just 1 hour and 9 minutes behind the second place multihull sailed by SwampMonkee and Chainsaw in their modified Tornado. Great racing to the bitter end.

Photo Credit to my amazing fiance Taylor (AKA Ginger)

We had a rocket ship start in pole position with sails at full throttle and Code Zero pulling hard
Thanks again to Drain Plug Magnets for your support!!!

Mosquito touches down at Cape Haze Marina on the heels of Randy's speed machine 'Sizzor'. All was going well, no signs of anyone on the horizon behind us. 

Refilling water at Check Point 2. We fought our way up Indian Key pass for many many many hours. Finally resorting to pulling the boat against the current with a rope from shore we finally made it. Sails in the distance! we were not alone. Must sail faster. 

Alan, slogs back to the boat with water before pushing off and leaving CP2. 
With the tide fighting us on the way in and again on the way out, it took every ounce of sailing skill and paddling brawn we had that day to get our craft away from the unforgiving pit of despair that is Chokoloskee. We cracked both dagger-boards (although they both still functioned) on our way back out into the gulf first running aground in a 3 knot current and getting wrenched around on the tip of the board and then headed out into open water when we struck an unidentified floating object. 

For comparison: Sambasailor and SailsAlot demonstrate above the gentlemen's method of making landfall at Check Point 2 on "the good tide" notice the LACK of mud and ABUNDANCE of water. We are taking notes. 

After another long night sailing into Flamingo (Check Point 3) and with very little to no sleep, Jake demonstrates proper form heading up the ICW to Key Largo. SwampMonkee and Chainsaw were hot on our heels just a few miles to our North making their way across Florida Bay.

Happy sailors arrive in Key Largo

Self Explanatory

Mosquito takes a well deserved rest in the warm clear waters of Key Largo and enjoys the sunset

I will find time to write up my personal experience of the race as I did last year but in the mean time Jake (AKA PopTarp) is hard at work on a video of our adventure using monologue and gopro footage from the race so check back soon for VIDEO!

On my plate this month? Starting new construction of a Core Sound 15 for a customer in Charlotte and also owner of Drain Plug Magnets who sponsored Jake and I this year in the EC.

In my spare time I am also doing a little scratch and dent work for watertribers Kiwibird and KneadingWater. They managed to really beat the crap out of their kayaks in this years EC and I will have pictures up of the work done on their kayaks.

Also, keep and eye on watertriber Sundance's trimaran kayak build blog. He is anxious to get back to building after finishing this years EC with his daughter in a Hobie TI.

Tuesday, March 04, 2014

Jarhead and Leatherlungs leave key largo

2:33pm tuesday. They got some breakfast and tried to sleep. Off they go.

Hanging out at the finish...

We have been hanging out here in Key Largo and got a good nights sleep last night. We finished at 4:50 last night, just in time to go out to dinner. It was a pretty tough race with a higher level of competition than I ever remember. Unfavorable tides and current into and out of check point 2 really knocked our lead down and SwampMonkee and Chainsaw in their Tornado were able to catch back up to us. In the end their decision to head across Florida Bay coupled with our decision to try and get a couple hours sleep at Flamingo was enough to give then the lead. They finished just an hour and a half ahead of us.

As always, hanging out with the finishers, talking about the crazy tides and sleep deprivation is great fun and we are having a nice time relaxing and talking about boats. 

Saturday, March 01, 2014

Everyglades Challenge: And they're off!

Jake and Alan set off at 7:00 this morning. Both were in great spirits; they got a good nights sleep and had a relaxed morning on the beach. 

Alan reported earlier that they were struggling through some light wind. Looking at their personal tracking page, they're speeding up. 

You may have noticed, The Watertribe Tracking Page is overloaded. The Race Manager and the Checkpoint Captains are asking everyone to stay off the tracker in order to give it time to reload.