Day 18


I sanded the entire hull smooth over the past few days.  I didn't take any pictures of that but not to worry, you didn't miss anything.  The manual doesn't say to do this, but it seemed to me that it will be easier to go ahead and level the hull coat before applying the deck fiberglass so that the overlap will have a very smooth surface to attach to.  Looking back now I probably would not have done it this way because I don't think it made any difference, but it's what I did so it goes here.

Here is the boat with the hull completely sanded.  The glass is still there under a very thin coat of epoxy even though it doesn't look like it is.

Step one in preparing the deck to be glass (other than sanding it) was to apply a strip of packing tape around the entire hull.  This is the line where the glass will overlap and adhere to the hull below the sheer panels.  Everything below the top of the tape will be trimmed off, sanded smooth, and feathered in.

Just as with the hull glass, the fiberglass sheet was laid out over the entire deck.

Then it was completely smoothed out by hand, again stretching the glass weave on the bias to make it conform to the shape of the deck.

Next I trimmed off the excess glass.  In retrospect I probably would not have done this, as the excess glass would have helped with catching drips, but the manual said to do it so I did.

Mixed up a large amount of epoxy and spread it over the fiberglass with a plastic squeegee.  It was a hot day and the epoxy started heating up very quickly in the cup, so there was no way I could take pictures while doing this.  Here is the finished result.  You can see the drips below the edge of the glass and the packing tape.

After the epoxy cured for about 4 hours I removed the packing tape and trimmed off the excess glass with a razor knife.  I also removed the glass from the cockpit opening and the rear hatch.

After a several more hours I used my carbide scraper to smooth out the rough edge of the glass.  Since there is already a layer of fiberglass under the edge, having the top layer be extremely thin should make the work of feathering it in much easier.  Again in retrospect I think not sanding the hull before glassing the deck probably would have had the same or a better result with less work.

After the epoxy had cured 8 hours and the edge of the glass had been smoothed over, I applied an additional fill coat to the deck glass and a thin skim coat to the hull.  The overlap is still barely visible but will disappear as the weave is filled in.