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Old 08-11-2011 | 01:46 PM
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Hydro Junkie
 
Joined: Nov 2004
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From: Marysville, WA
Default RE: Re-Engineering A Dumas Pay'N Pak

With the sponson transoms installed and secured to the nontrip panels, I now turned to the sponsons. A 1/8" square spruce glue rail was installed to the inside the bottom edge of the sponson inside. Frames that were not finished previously were now finished, including the addition of lightening holes and epoxied to the sponson insides and engine bay walls with 1/8" square spruce glue blocks. I made two partial frame 2s from 1/32 ply, again to cut weight, while the previously completed frame 1 and now completed frame 3 were fabricated from 1/16". Frame 3, like frame 1 that was made earlier, extended across the full width of the hull, adding rigidity to the hull where it was needed most, in front of the skid fin. With the frames now mounted, the sponson sheer rails were fabricated from 1/8" ply and installed. Once again, I had to deviate from the directions with how the sponson chines were done. The directions said to "glue on the 1/8" mahogany parts into slots on the bottom of the cross frames, sand the sheers and chines to match the angle of the frames and attach the sponson side". To me, the sponsons need to be built heavier than that so they won't fall apart. To this end, I cut out two sponson chines from 1/8" ply and epoxied them into place. I then added a 1/8" glue rail and attached it to the outside of the chines to increase the strength and gluing area. Another glue rail was added to the inside to increase the area to attach the sponson bottom. A 1/4X3/16" glue block was now attached to the outside of the sheer/chine joint and the sheers and chines were now sanded to give them parallel gluing surfaces and glue blocks added to the outside edge of each frame. Since the chines were now heavily overbuilt, I removed a considerable amount of ply above the glue blocks using a Dremel tool. A final sanding and the sponson frames were now ready for skinning. At this point, I got away from woodworking and into set up. Rather than fight around the skin later, I machined a skid fin bracket and installed it using machine screws and blind nuts. I also installed threaded inserts into the bottom inboard corners of the sponsons as well as the bottom left corner of the underdeck area through the boat's transom. I'll stop here for the day and continue tomorrow. I have several boats that need building and a couple that are being reworked so...................................
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