Major progress

I got so much done on WiTHiN this weekend.

I set myself a deadline of this next weekend to have WiTHiN ready for water testing. Stefan organized a local pool for me for Sunday night, so now I have to get everything finished. If you are local, come on out to the pool test on Sunday night 7:00 pm to 8:00 pm. It's at the YWCA on 5th downtown (note - NOT the YMCA).

First, I glassed in those longitudinal bulkheads. I cut out 1/2" thick Styrofoam boards and then covered with fiberglass Roving and whetted out with epoxy resin. Then instead of vacuum bagging, I wrapped the boards tightly with shrink wrap plastic and placed them under a flat board with a couple hundred pounds on top. This worked out better than bagging, as there was no creasing of the glass fabric.

I plan on pouring expanding foam into the space between the bulkheads to finish the wide gunwale.

Ben came over to help and he worked on cutting out some foam for a plug for the drive leg well. I finished up the plug by capping it with a piece of plywood and a handle from an old sanding block. This fits the hole in the drive leg bay very tightly. I glued on the cut-out from the kayak bottom so the bottom of the plug is flush to the bottom of the hull. I still need to sand down the epoxy drips, and I can also fill in the gap between the plug and the hull with a silicon bead, then slice it with a razor. I have no idea if this is going to leak or not....

I added two triangular plywood panels to the spaces in my drive leg, then filled it up with epoxy/micro filler.

I made an adjustable seat back support with two pieces of plywood. An aluminum rod runs between the two ratchet style supports mounted on each long bulk. I placed a foam sleeve over the aluminum rod to more evenly spread out the weight of the seat back - this works very well. Now I can not only move my seat forward or back, but I can also adjust the seat back angle up or down.

The last item was the rudder. I was going to rig up some line and pulleys, but I played around with a long plastic tube I had and found that if I supported the semi-flexible tube once in the middle, it was VERY stiff, strong and light. Probably not something for ocean conditions, but I think it should do fine for a calm lake. The steering lever is some old bike parts I have that I put together. Two carbon tubes with a slip fit - the larger diameter one bonded into the gunwale, and the smaller diameter tube with a small handle bar clamped to it. The other end has a threaded rod with a swivel rod end on it which guides the long plastic push/pull rod. The push/pull rod runs though a small plastic sleeve bonded to the gunwale in the stern and up to a handle bar stem that clamps onto my rudder steering tube. It all works fairly slick.

nest on the agenda is the prop - I'll start that tomorrow after my CSS school KidPower presentation. Then I need to make up the drive leg bay lip, and I should be able to finish everything up and attend to the details by Friday-Saturday. Should be all ready for the pool test on Sunday.


2 Responses to “Major progress”

  1. # Anonymous Anonymous

    Hi Greg,

    Ha. Now I'm imagining a scene from Waterworld, with you out in the middle of the ocean with some broken CF part, trolling other boaters for some resin ...


  2. # Blogger DDeden

    Greg, I just saw some no-shift automatic 3 speed coaster bikes, I'm guessing you already know of them, but just thought I'd throw that up.

    Might it be of use to have more than one gear size? If periocity of waves varies between flat and bumpy during the ride, I don't know the extent of such effect on muscles. Maybe it's insignificant.


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