Rudder Mold and first part.

The rudder plug and both molds.


The first rudder skin, three layers of 6oz cloth, one layer of 6oz kevlar, and one layer of 6oz uni S-glass all in the bag.

Taking the J46 from Georgetown to Chesapeake City

Taking my brothers J46 from Georgetown to Chesapeake City on a Monday in the spring with no one on the bay. Weather was nice with a 18 kn out of the NW.http://www.youtube.com/watch?v=P0jyHQz3cg0

Tiller heads are mostly done.

Made two tiller heads using carbon and s-glass, I need to create a jig to drill all the holes that are needed.

Mast Rotation

I made a mast rotation controller.
Went to the local Golf proshop and got a few carbon fiber driver shafts that had been broken at the head end.  ( it seems that this is a frequent issue with golfers) Then cut them to length and glued on to tabs to bolt it to the mast than bridged the trailing end wit carbon fiber.

Tooling for the Tiller Head.

The tooling for the rudder head and tiller.

 

New rudder for a mold.

My old 18sq rudders (summer light air, lake sailing) where not effective last year when I used them and the set of NACRA rudders I have weight to much, so I thought I would modify one of the 18sq rudders and make a set of molds so I can make carbon rudders.
The one on the left is one of the 18sq rudders and the one on the right is the plug for the mold.
I cut the tip square and glued on some balsa wood. .Then shaped it with a plane and sanded to shape. Then a coat of epoxy and more sanding then primer.

The Centerboard Mold

Removed the mold off the plug.

Starting Centerboard Mold

So, two coats of epoxy, sand.
One coat of high build primer, sand (400), sand (600), sand(800). Buff out with compound, buff out with glazer-sealer. Four coats of wax, wait 24 hours four more coats of wax.
Wipe on a coat of PCA. One layer tooling gelcoat, then a layer of 3/4 oz mat, and one layers of 1.5 oz mat. Let it cure overnight three layers of 1.5 oz. mat then a layer of 10 oz tooling cloth.

Have I ever mentioned how much I hate Polyester resin? I should have worn my respirator.

Center Board Plug came in

Center board plug came in, I built a frame for it and put on to coats of epoxy.

Ordered a Centerboard Plug

I ordered a centerboard plug from Phil @ fastcomposites.ca.
It is a 63A010 section that is 1300mm X 150mm.
I hope I can make it stiff enough so it does not twist.
Next is the new light rudders.
Any one have a profile suggestion?