Thursday, April 28, 2011

USA 9042 Rigging - Getting closer to a test sail

Guy turning block riser plates were molded on the boat for a proper fit to the curvature of the deck. Packing tape and polystyrene foam were used to make a male mold. I use some McLube on the packing tape to help the part release easier. Make sure you leave the mastic covered until the wetted out cloth is on the part and you are ready to lay the bagging film down. if you get epoxy on the mastic, you will not get a proper seal.
Layup stacks ready to be wet-out on cardboard. I used 2 layers of 8 oz carbon twill on the top followed by 3 layers of 6 oz s glass followed by another layer of carbon twill on the bottom. Preparation is key for the vacuum bagging operation. Everything should be pre-cut and staged where it needs to be. Especially when your work partner is playing golf in California and you are working alone.
Shroud tracks were ground to fit the curvature of the deck and bedded in epoxy and filler colored wit black pigment. A small fillet was used on the bottom edge to finish the install.
1/4" G10 plates were bonded on the side of the centerboard case to mount eyestraps for some shockcord take-ups. The plates were drilled and tapped before they were bonded in. Use some sacrificial hardware coated in McLube to keep the epoxy and filler from filling the tapped holes. These plates were masked and painted with a rattle can.
Custom quintuple block mounted on the forward bulkhead. This block was made using Harken 16mm self-contained sheaves with 1/16" carbon disks between. Duralac was used on all the carbon/stainless interfaces to prevent corrosion. This block is to lead 5 shockcord passes under the launcher tube; 3 for the trapeze take-up and 2 for the foreguy.
Another bonded G10 plate for the trapeze and foreguy shockord.
Turning block for the guy control line led aft along both seat tanks. This G10 plate was bonded in with 1 of the 4 fasteners through bolted on the diagonal bulkhead. This was a tricky install due to the complex angles involved.
Under deck launcher cleat hardware mounted to G10 plates. Note that the deck on this boat will be super clean as none of this hardware is through bolted. There is just a bullseye where the line exits and the Melges flanges on the aft face.
Aft centerboard case detail.
Guy turning block riser plates being vacuum bagged. Note that the suction cup is placed outside of where the part will be taken from.
Riser plate unmolded, trimmed and sanded. These turned out great and will get clear coated.

More pictures in the GALLERY.


  1. Where did you get the flanges for the aft exit of the launcher line?

  2. They're from Melges and can be found here: