Thursday, September 22, 2011

Fabricating Closure of Hole at Junction Point of Stern










A problem arising was an unwanted hole at the bottom of the hull which was the result of the aluminium sheeting inset to finish the shape of the stern and provide good support for the pintels and rudder. The size of the gap, shown in the first picture, is about that of a large kiwi fruit and is complicated in its surround by the overlappin plates and the attendant rivetting nearby.
It was tempting to just put a ball of fibre glass into the gap, work it to a good shape, and secure it with screws. However in keeping with the general nature of the hull's build I made it in aluminium. This started with a paper cut out to fit the round and angular components of the hole. This was then spread out flat and marked out on ali sheeting, formed and welded along its seams to produce a 'cup' which fits nattily over the defect.
It will be secured with rivets and a ss machine bolt and nut after being set in place on a bed of Sikaflex 291i.