PA180001.jpg Before the Destruction. *Note* Right click on photos to open in new window. PA180002.jpg Lots of tired looking marine ply. PA180003.jpg Thanks to Braeden, he blew the side of my boat out with his hip when he thought he could sail in 25 knots. PA180004.jpg Bracket location for plank attachment. Time to get rid of this outdated system. PA180005.jpg The paint has held up pretty good for being 10 or more years old. PA180006.jpg The crack from the inside. Notice the varnished rails. Say goodbye to all of this. PA180008.jpg Rail #1 removed. What a pain. PA180009.jpg As promised... the destruction. Taking the thing apart always proves to be the easy part. PA180010.jpg More destruction. Structurally, it has held together quite well over the years. That is probably attributed to the fact that they used a ton of nails to hold the damn thing together. PA180011.jpg Rear deck ply taken off. PA180012.jpg Time to take off the bottom. PA180013.jpg Marine ply all gone! PA210014.jpg Time to take that other pesky rail off. PA210018.jpg Finally done with both rails and marine ply. This is halfway through the stripping process. PA210021.jpg *WARNING* If you use paint stripper in an unventilated space for three hours and don't use a respirator... you WILL look as shitty as this guy right now! I was sick for 3 weeks because of that. PA210022.jpg A pile of chunked marine ply, stripped paint, and chemicals. PA240026.jpg I've started stripping, sanding, and fairing all the nicks, cracks, and holes in the hull. PB110050.jpg Here's Mike soaking the carbon in resin. We're reinforcing the sides of the DN's with carbon to mitigate the cracking situation that happens with all DNs. PB110051.jpg Using the squeegy to really soak the carbon. PB110052.jpg Cutting the roll into strips for the sides of the boats. PB110053.jpg The carbon laid on. PB110054.jpg It all got fairly good contact with the boat. There were a few air pockets which have to be chipped out and filled/faired. PB190058.jpg Time to put on some bombproof rails. PB190059.jpg Really got some good squeeze on these rails. PB190060.jpg *Note* You can never have enough clamps IMO. PB190061.jpg Don't know what prompted this, but Stefan is now angry... PB190063.jpg ... and so retaliation ensues. PB190064.jpg This is all Mike really comes over for. To sweep the floor and drink beer. In his defence, he brings the beer. PB190065.jpg He has learned his lesson and wears safety goggles around me from now on. PB190066.jpg The carbon has been sanded and all the ribs in the cockpit have been replaced with newer, beefier parts. PB190067.jpg The rails have turned out quite well. It worked out great because the inside carbon ties into the cockpit ribs, and the outside carbon ties into the rails. PB190068.jpg Optimizing usage by tracing the boat parts onto the 4x8 sheet of Marine Ply. PB190069.jpg Here's one way to make a sheet disappear quite quickly. PB190071.jpg Umm... PB190072.jpg Attaching the bottom skin. PB190073.jpg Make sure that there is visible squeeze on all joints on the boat. If there isn't any visible (even a hair) then there are potential problems down the road. PB190074.jpg Forming the cockpit fillet. This will prevent cracking in the future and is a nice finish detail in the cockpit. PB190075.jpg Using blocks to get clamp pressure everywhere. PB220082.jpg Cutting the blocks to accomodate the bolt. PB220083.jpg The cut was made just deep enough to make the bolt flush with the edge of the block. PB220085.jpg These blocks required some creative clamping to get enough pressure. PB220086.jpg I drilled slightly into the central rib to accomodate the head of the bolt. PB220087.jpg The view after both are installed. PB240001.jpg View from the bottom where I attach the springboard, which will extend off the bow. PB240002.jpg Epoxying the rear deck on first. PB250015.jpg After the rear deck epoxy sets, I then scribe the ends of the caps (for the rails) to the rear deck so they butt flush when the gluing starts. PB250016.jpg Aligning the caps with the sides/rails. PB250017.jpg I'll cut the cap here, and then butt the fordeck into both rails which ensures a flush joint. PB250018.jpg Mixing up the epoxy and microballoons. PB250022.jpg Final stage of the clamping. Almost there. PB250023.jpg Once it dries, I can flush-trim the deck skin and then use a radius router bit on every exposed edge. PB280027.jpg After flushtrimming, I cut the end of the rails back to meet the side of the boat. I then went back over everything with the radius bit. PB280029.jpg Here I beltsanded the top ply back to meet the curve of the tailcone. PB280030.jpg Another angle of where the rail meets the side. PC040038.jpg After a few coats of bondo. This stage really made me hate the fairing process. PC040039.jpg After a bondo coat on the inside of the cockpit. PC080042.jpg Cut and bevelled the plank blocks on the bottom of the boat. PC080043.jpg Gluing the blocks to the bottom. PC160057.jpg My friend Sean happily volunteered his expertise in finishing during the primer/finish coat stage. PC160058.jpg I chose Burnt Orange for the finish color. I hope it turns out great on the ice.