1963 Alcort Wooden Sunfish CHIP Restoration

signal charlie

Well-Known Member
Staff member
Thread starter #22
Primed the cockpit, easier to paint it now, before the bottom goes on.

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Repaired the stem with THIXO.

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Repaired errant cuts with THIXO, the cockpit bulkheads need to be watertight. We found out that there are High Thrust caulk guns recently, 18:1 ratio makes it a breeze to dispense thick materials. Bought our from Jamestown Distributors.

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Made paper patterns for the fore and aft bottom panels.

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signal charlie

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Staff member
Thread starter #23
Marked the patterns with the stringer locations.

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Hoping to use a good section of the old hull for the floorboards.

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Brushed on a coat of TotalBoat WetEdge Oyster White. We're hoping it's close enough to the BluGlo White that we don't have to order more paint.

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L&VW

Well-Known Member
#24
Just like the Minimax and Minimost, designed to take advantage
of 4 x 8 plywood sheets. Anyone care to list any
additional '4 X 8' boats kits? I believe the original glue that
was used at the time was powered Weldwood.

These things would be perfect for a laser cut kit if you had
the hardware on hand. Thanks to the 2 inch mast hole they
will never go metric
.
Two inches works out to 50mm. (Close enough). ;)

I built two Minimax hydroplanes, when I should have been studying in High School. :oops: In the second example, I had designed new added features that mimicked a "tunnel-hull" design—whose designs were coming out about the same time. :)

Instead of ending the two sponsons just ahead of the driver, if I had continued the sponsons forward, I'd have had the great "lift" that made tunnel-hulls famous. (Or infamous for flipping over backwards) :eek:. Instead, I designed insufficient "down-vents" that would occasionally reverse direction and spray a fine mist across my glasses. :confused:

Weldwood powder is described as a "resorcinol glue"—and is still being sold.

Invented in the UK, resorcinol glue was used to build the molded-plywood "Mosquito medium bomber" in WWII—nicknamed "the balsa bomber".

As for the use of 4'x8' plywood sheets, I still have Mechanix Illustrated (paper) plans for a "Mustang" 10-foot runabout. Could that be an Evinrude 3.3-HP outboard? :confused:

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signal charlie

Well-Known Member
Staff member
Thread starter #25
Fastening the panels with THIXO and silicone bronze ring shank nails.

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SIlicone bronze screws for the keel strip.

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Trimmed the bottom panels.

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Filled the grain and screw holes, covered nail holes with TotalFair.

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Ready for sanding.

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L&VW

Well-Known Member
#26
Repaired errant cuts with THIXO, the cockpit bulkheads need to be watertight. We found out that there are High Thrust caulk guns recently, 18:1 ratio makes it a breeze to dispense thick materials. Bought our from Jamestown Distributors.
West© Systems makes a 6-TEN© epoxy in a 10-oz tube (which sounds similar to THIXO©), available at West Marine© stores. Of the clever 2-part mixing devices that attach to the 10-oz tubes, one comes with it, and are available separately, too.

If you're in real hurry, $100 dispensers are available that are air-powered. Caulking Guns

.
 

signal charlie

Well-Known Member
Staff member
Thread starter #27
As for material dispensers, I've seen Snake Mountain Boatworks use the air gun to dispense 5200. I can't imagine what the material cost is to use the many tubes necessary for a No Soak bottom on a Chris Craft or Century restoration. It takes about one tube of THIXO or Pettit Flexpoxy for each one of the 4 panels on a Sunfish bottom, we put a double bead on the side plank edge and a double bead on the panel, plus the material needed for the keel strip and bulkheads.

The Flexpoxy we have bought from West Marine or Jamestown Distributors, it runs several dollars more at WM. JD also carries the six10 also, not sure about the gflex. As for cost, the THIXO is the lowest cost, and TotalBoat ships free Domestic US. There might be a small HazMat fee added, but that is the same for all of those products. We order enough stuff from JD that we pay $50 for the VIP membership each year, and get free shipping. We also are Ambassadors for the TotalBoat line, and get free stuff and a discount. If anyone wants to try the TotalBoat products, send us a private message and we can pass along our 20% discount code.

Looking at the pictures above of a green hull reminded me, we have used Pettit EZFair in the past, it mixes up light gray vs green, and covered just a bit easier with follow on painting in mind. If the next thing going on is primer it really doesn't mater the color of the fairing compound. It also came in the 2 part caulk tubes, which were GREAT for small projects, dispense a small amount without messy stir sticks, then put the cap back on. It stores well. We used quite a few tubes fairing the seams on the 1880s rowboat BARBASHELA's restoration, since it is a softer fairing material we thought it was a good substitute for seam compound and much easier to work with.

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