Optimist Club Racer
Posted: Mon Nov 02, 2009 4:06 pm
This thread will document the building of our Optimist Club Racer.
UPDATE: http://www.youtube.com/watch?v=jwVlLMeB ... re=feedbul
I will insert some of the pictures from the Club Racer gallery into this thread, but there are many more pictures here..
http://gallery.bateau2.com/thumbnails.php?album=1096
We start with a basket mold which is cut on our CNC machine and is self-aligning. This mold also has inside wolds which force side and bottom panels perfectly into shape. The Club Racer can be built by anyone, and does not require the basket mold. The purpose of the basket mold is to allow sailing clubs or schools to build many boats at a time with minimal setup required. basket mold will be sold separately from the Club Racer Kits.
mold parts
Basket mold assembled (one inside mold for picture)
side and bottom panels placed into basket mold
insert male molds
Coat joint area with epoxy before laying down fillet
use caulk tube to apply a bead of epoxy fillet putty, immediately smooth out bead into fillet shape using approximately 3/8" radius tool (about the size of a tongue depressor)
While fillet is still malleable (but not soft) lay your biaxial tape into the joints. The holes in the chine corner of the molds allows for tape to be passed from transom to transom
Wetting out the fiberglass tape
The boat now sits in the mold overnight to allow glass joint to cure. In the mean time we started making the dagger board case and the mast partner frame.
Mast partner frame is three pieces: the partner, frame, and cleat
We dry fit all the parts and hold them together with drywall screws (pre-drill pilot holes so you do not split the plywood)
epoxy glued together. we back out the screws once the epoxy cures. Make sure frame and partner are at a 90 degree angle
dagger board case:
sides and cleats are epoxy coated, the a second thicker coat of epoxy/graphite is applied to the inside surface (makes case super slick and abrasion resistant)...
UPDATE: http://www.youtube.com/watch?v=jwVlLMeB ... re=feedbul
I will insert some of the pictures from the Club Racer gallery into this thread, but there are many more pictures here..
http://gallery.bateau2.com/thumbnails.php?album=1096
We start with a basket mold which is cut on our CNC machine and is self-aligning. This mold also has inside wolds which force side and bottom panels perfectly into shape. The Club Racer can be built by anyone, and does not require the basket mold. The purpose of the basket mold is to allow sailing clubs or schools to build many boats at a time with minimal setup required. basket mold will be sold separately from the Club Racer Kits.
mold parts
Basket mold assembled (one inside mold for picture)
side and bottom panels placed into basket mold
insert male molds
Coat joint area with epoxy before laying down fillet
use caulk tube to apply a bead of epoxy fillet putty, immediately smooth out bead into fillet shape using approximately 3/8" radius tool (about the size of a tongue depressor)
While fillet is still malleable (but not soft) lay your biaxial tape into the joints. The holes in the chine corner of the molds allows for tape to be passed from transom to transom
Wetting out the fiberglass tape
The boat now sits in the mold overnight to allow glass joint to cure. In the mean time we started making the dagger board case and the mast partner frame.
Mast partner frame is three pieces: the partner, frame, and cleat
We dry fit all the parts and hold them together with drywall screws (pre-drill pilot holes so you do not split the plywood)
epoxy glued together. we back out the screws once the epoxy cures. Make sure frame and partner are at a 90 degree angle
dagger board case:
sides and cleats are epoxy coated, the a second thicker coat of epoxy/graphite is applied to the inside surface (makes case super slick and abrasion resistant)...