Day 41, 8/6, Put front sail back, Windex, VHF antenna and cable, window ports installation.

Mast, sails.

Preparing to sail lake in 2 weeks. Mast stays well, all stays tighten, and adjusted, Furler fixed. Put Genoa back after furler and front stay repair. 

Repaired the sail, it had teared umbrella cover and some stitches in spreaders touching area area. now it looks like new. And, yes 34' boat Genoa is a big cloth!

Furler tested, works well everything is moving as expected. 

 

 

Mast top

Had one more travel to mast top, it is very simple with  permanent steps. As part of sail day I planned in two weeks, I would like to install Windex,  installing windex i need to make sure VHF antenna is not interfering with it, so install antenna as well, but antenna cable is very old and not good to be used any more, so I replaced cable as well to molded in connector on the mast top.

Windex installed

Windows

Long day - Route new openings for 5  windows. 

 

I used CNC machined template to cut openings with proper angle to horizon. Template is made from two parts one - main then 1/4 inch flat with one side beveled

in thickest place I need to cut through the outer skin ~1/4" fiberglass  3/4 inch original plywood thickness of angled spacer ~ 1/2" and  1/4" internal plywood and all this is not 90 degree penetration. so even with my 2" long router bit i was not able to cut. So I put both templates, route opening, as deep as i can, remove add-on part of the template and cut deeper on the top of the opening.

A lot of wood and fiberglass dust.  

Instilled windows with 3M5200 maybe not the best choice, but it is what manufacturer strictly recommended.

Before install window I forcefully wet the windows opening with sealant and then put it on the window and inserted, clean excessive 5200 and add in some places to make solid piece of polyurethane between window and cabin top through all layers of plywood and fiberglass.

   Not a lot of words, but a hell a lot of work, cut , clean, put masking tape seal and figure out how to put external decorative plates on the curved surface and compress them to keep all together.

as usual sand bags help someway ;-)