Tying up loose ends (literally)

Before I go on, I'd like to add another photo of the finished hull, this one taken from the side.  In the last post, the wide-angle camera view made the proportions look deceptive.  This should give a better idea of the boat's freeboard and the relative positions of the two masts.  I find the rake of the masts a little, well, rakish.

I made some good progress in the past week.  A whole bunch of little things still needed to be checked off before finishing the rigging.  I varnished the floor with non-slip grit mixed in, screwed the middle plank over the ballast box, and laid the floor in its place.  I fitted the sliding door on the main bulkhead and glued and screwed its lower rail.  You can see the finished interior in the second photo--looks nice and roomy, does it not?  I put the brass hinges on the three flip-up locker doors, but I haven't installed closures yet.  I have had a hard time deciding how to keep these doors closed (in case of rough weather or a capsize)--the setup isn't right for latches, so I considered using bungee cords and hooks, but I decided they wouldn't look right.  I am thinking of using little pivoting flat blocks of wood, but I don't feel there is much hurry for them.  I also installed a watertight inspection port on the foredeck, and two in the seat risers for access into the buoyancy compartments.  Finally I touched up the hull with blue paint up to the rubrails--I had left an irregular patch unpainted so I could glue the rubrails on.

I also sanded the masts, yards and oars and gave all two coats of varnish  Then I finished both sails--I had a few reef patches to sew on, batten pockets to sew closed, and a whole lot of loose thread ends to tie and trim.  In the coming week I will start on the rigging.  First I will lace the sails onto their yards, then I will attach the halyards to the yards, then install blocks and cleats for halyards, sheets and snotters, then set up the tack downhaul systems, the clew snaphooks, and finally the lines for pulling up the centerboard and rudder.  The end is in sight!

All but the running rigging (almost)

In the last few days, I started by filling the ballast box with lead shot, 50 lbs of it.  I used silicone caulk and styrofoam to seal it into its two compartments (see first photo: forward compartment after the styrofoam went on, aft one before).  I will be screwing the middle floor plank on top.  Then I finished assembling the floor.  It was quite tricky because I had to do everything upside-down, since the cross pieces were glued and screwed on the underside.  Of course in a home-designed and hand-built boat nothing is exactly square and even, so I had to do some sanding, trimming and dealing with inevitable small mistakes after assembly to make all three parts of the floor fit properly.  In doing some of that I managed to cut my left thumb with a detail saw that slipped; not deep enough to need stitches but it took some work to stop the bleeding.  It was the first (and hopefully last) mishap I've had that needed as much as a band-aid.  Anyway, a good reminder to always be careful.  I also drilled ten 7/8-inch holes in all in the floor assemblies, two (one port, one starboard) for each space between frames.  The holes are for pumping the bilges dry, extra ventilation and for my fingers so I can pull the floor up as needed.

Then I reinforced the bow from the inside with two strips of 3/8-inch plywood, and drilled the holes for the U-bolt that will hook to the winch. Then I sanded tops and insides and laid on the first coat of varnish, followed by the second.  Then I gave three coats of white paint to the fore- and side-decks.

I also gave the floor assemblies a coat of epoxy.  They will be varnished next week, mixed with some non-skid grit additive to reduce slipping.  This plus a few other things (like touching up the blue hull paint below the rubrails, locker door closures, installing the three inspection ports with white caulk and screws, and screwing on the middle plank) account for the "almost" part in the title.

Then, on Sunday, on the first anniversary of beginning the physical boat building (the planning of course went on a lot longer than that), I and some friends transferred the boat from its cradle to its new trailer.  Thanks, Gregg, Mark and Ralph! (second photo). 

The last two photos are of the (almost) finished boat (minus the running rigging).   Isn't Aerie a beauty?

In the next 2-3 of weeks I hope to have everything ready for launch, barring any unforeseen issues.  So keep checking 176inches.

boatbuilder