Vacation ;) days 54-58 10/28-11/2. 36 hours work.

Big sprint  days 54-58 10/28-11/2

Deck

Deck handles installed. Handles bolted to deck with bolts from under beneath. Installation went mostly  well.  All bedded with butil tape. Run 2 hours water tight test - no problems.

 

All but one place they bolted with 3/8 bolts. Provide descent strength.

Long Portside handle, second mount bolt substituted with big self-tapping screw.  It appeared one insert is loosed and not holds well in wood. Fortunately I was able to put about 1-1/2 inch  in wood body and it is mount in middle between bolted places, so I think it is some compromise, but should work for years.

 

Water system

Day Water tank finished, filled with water, no smell, or feel able taste di

 

 Tank repaired, coated with drinking water grade coat.

Original fresh water tank cover on left. It was just painted plywood. I do not have imagine what paint was used, is it good for drinking water. I know plywood+water -> problems, does not mater what kind of ply or paint it is. So i decided to manufacture new lid form food grade material HDPE.

 Lid installed including electric water level sensor.

 Try to run water system, found the old facet is leaking, so i replaced o-rins and have water in galley to wash my hands and face at end of the hard day.

Fix galley facet. 40 years old facet leak

Deck

Main rule:

EVERYTHING I DID NOT TOUCH ON THE DECK IS LEAKING.

Main sheet traveler rebedded

I have no idea WHY traveler frame in mounted with wood screws but there MASSIVE opportunity for leaking.

Traveler is mounted back.
 

Main cabin hatch frame rebuild

Coming one day in the morning and feel water dripping on my head. It appeared hatch frame was sealed with silicone. And sure it failed.

Leaking corner.

I took all planks off , cleaned, resurfaced.

 Set all back on 3M 4000 UV.

Little bit challenge in corners. But will see how it will work.

It took 3 hours, but now I have one less thing to fix later.

 Centerboard "goose neck" re-bed

Replaced wood-screws with  through screws, put it on butil tape.

 Small winch and centerboard line cleat re-bed, deck core rebuild under winch

 Took Winch and backing plate and understand there code is done.

Somebody made Swiss cheese there. 

From the top side

Holes drilled out and cleaned, countersinks made  

Gel-coat removed,holes filled with thickened epoxy and glassed over 3 layers 8oz cloth.

From under

Cut it open, clean rotted plywood blocks. I was surprised, only 3 squares were water damaged.

Dried and fill core space with teak plywood. I made wood blocks covering gaps in original pattern, so blocks inserted In between skins.

Dry-fit of wood core pieces

All space was filled with thickened epoxy then wood inserted squishing excessive epoxy out, then original skin put back. and glassed in 3 layers 8 oz.  

I know somebody will say it is not enough to fill 1/8 inch glass structure, but this winch is for centerboard lift and there almost no load. It originally was screwed on wood-screws.

Originally, Winch was installed with wood screws. Backing plate did do nothing, I replaced them with through screws and nuts.

<< final picture will be set>>>

Center board cleat  re-bed

Air Conditioner 

A/C output air distribution box

Built  Air conditioner output distribution box aluminum foil laminated 3/4" hard foam. Aluminum foil self adhesive tape, hot glue and duct tape. 

Laminated Polyiso Foam (https://www.homedepot.com/p/AP-Foil-3-4-in-x-48-in-x-96-in-R-5-Foil-Faced-Polyisocyanurate-Foam-Board-Insulation-90001014/320028593) is a great material - light, easy to work, flame resistant up to 800C . No smell or chemicals contamination to air due aluminum foil barrier.

Box sits on top of a/c outlet and duct-taped to it. also glued to step on the back side. 

Two electrically controlled chokes mounted as box output. Idea is to be able to direct air to main of fore cabin by choice.

Internal construction built as muffler with flow directors to make air flow loop from AC outlet to exit with  180 degree in one plane and 90 degree in another.  to help with flow resistance it has plates mounted under 45 degrees to eliminate air pockets in corners.

 

Air outlets in main cabin.

Duct pipe is going through bulkhead. insulation intentionally left to prevent plywood from wetting by cold duct pipe.

Two outlet box made. first has flow reflector "cutting half air flow to outlet next to bulkhead, other outlet is left from future galley shelves.

Inlet filter and box

Built Air conditioner inlet boxt using same foam. Main reason to build box vs just keep it in a locker - AC is mounted in the future cabinet area  and I want it to be self-contained before cabinet will be rebuilt  as well due to many dusty woodwork on the boat now i need to put air filter to protect AC evaporator.

12x12 inch filter placed

Just how it sit in place.

Interior

Prepare for ceiling installation, including under deck area in main cabin and head.