Keel box stiffeners/frames

Hew advised that frames or stiffeners should be added to better strengthen the keel box. This was accomplished by cutting some epoxied fiberglass to fit the shape of the hull and the sides of the keel box. Limber holes were cut into the frames to allow water to pass through. The frames also had the center cut out to minimize weight.

Above - The frames are dry fitted to the keel box/hull

Below - The frames attached to the keel box/hull with epoxy

Cutting keel box

In order for the deck piece to fit properly, the top of the keel box has to be cut to the proper height. This was accomplished by using the Dremel cutting wheel. You can also see in the photo a small piece of scrap epoxied fiberglass that will eventually by fitted on the top of the keel box with thickened epoxy to prevent water ingress from the keel box. Only a small hole will be in this 'cap' to allow the keel bolt to protrude into the cockpit where it will be fastened with a nut of some sort.

Keel box / Hull joint

Here are a few photos of the keel box / hull joint sanded smooth. Again, this area still requires some work after the deck is installed.

Removal of Keel from Keelbox/Hull

It took some salty words to remove the keel blade from the keel box that was epoxied into the hull. A bit of advice, use mold release when ever you think it may be necessary!

After removing the keel blade, I cut the exposed tabs of the keel box with the Dremel cutting wheel and the used a block sander to manually sand down these tabs flush to the hull. As you can see tape was used to protect the finish of the hull. Eventually more work will be required in this area of the hull/keel box joint. Some more epoxy with micro balloons will be needed and then a final sanding to make the fit smooth.

Forward Frame

We took a scrap piece of circuit board material (a piece of fiberglass with epoxy) that was donated to our group and cut it to fit the underside of the deck and the inside of the hull in an area between where the No. 1 and No. 2 jib will attach the hull. This frame will hold blocks for the sheets and the bungee cord as well as offer strength and support of the hull/deck.

Sail Servo Bracket

I removed the fiberglass that was molded over a 2 X 4 the previous night and fitted it to the hull in the area we felt it would go. This would be fine tuned and adjusted when we had more of the interior pieces rough fitted. Later I will cut a hole in the bracket to allow the sail servo to fit.

Foredeck Stiffener

I removed the weight and plastic from the underside of the foredeck stiffener. A piece of spruce was used to add some support and strength to this part of the foredeck. Epoxy was spread on all surfaces of the spruce to avoid any water damage.