The Gougeon Brothers on Boat Construction - WEST SYSTEM Epoxy

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214 First Production Steps <strong>The</strong> Keelson Keels can take many shapes and forms. <strong>The</strong> design shown in Figure 19-8 is one of the more successful solutions to the problem of distributing high point loading, as might be generated by a ballast keel, over maximum area. This type of keel and keelson assembly is basically a relatively lightweight I-beam with two faces separated by blocking along the length of the boat. Laminated floors and frames distribute load athwartship. Keelsons are usually made of dense woods with high strength. Mahogany, for example, is a good choice. We generally install keelsons after removing hulls from their set-ups. <strong>The</strong> keelson is laminated over the floor and core blocking to form a single unit. Hardwood keelson Blocking <strong>The</strong> structural advantage of this keelson concept is excellent longitudinal stiffness and strength at a light weight. <strong>The</strong> major advantage, however, is the large safety margin that this method of construction can provide if you ground with a modern, fin-type ballast keel. Grounding on a rock can produce severe loading on the entire keel and adjoining structures as the aft portion of the ballast keel is forced upward into the hull. <strong>The</strong> beauty of the keelson concept is that the complex is capable of absorbing a great deal of energy by putting the bottom keel and hull skin in compression and the keelson in tension, which is wood’s strongest property. Often, a severe grounding will cause the keelson to break in tension. It will absorb tremendous amounts of energy in the process with the positive result that no other part of the boat is damaged. <strong>The</strong> Laminated frame/floor Keelson Fore and aft keel blocking Planking Planking Laminated floor timbers Limber holes Athwartship blocking under frame Limber hole Figure 19-8 Detail and cross section view of a keel and keelson assembly. This design offers light weight and good distribution of the high point loading of a ballast keel. Keel Keel Ballast keel
Chapter 19 – Keels, Stems, and Sheer Clamps 215 Shock loads from grounding and resultant force on keel cause tension break in keelson Grounding force Figure 19-9 <strong>The</strong> effect of grounding on the keelson. Shock loads from grounding and the resultant forces on the keel cause a tension break in the keelson at the back edge of the keel. keelson is relatively easy to repair by simply scarfing in another piece in the area that has been fractured, and the repair costs little in materials or labor hours. This is a great savings when compared to the possible damage that the hull itself might sustain without this arrangement. (In two instances, large IOR boats that we have built have had major groundings on rocks. In both cases, the keelson concept worked beautifully, absorbing most of the energy that was generated by the tremendous grounding forces.) Another structural advantage is that you can make the lower keel itself much smaller than normal, permitting laminated floors or ribs of the maximum size to pass across the keel with the minimum amount of notching. This provides excellent athwartship load distribution and provides maximum usable headroom space in the process. <strong>The</strong> keelson represents a very efficient use of material and takes relatively few hours to manufacture. Centerboard and Daggerboard Cases Centerboard and daggerboard cases are, in effect, extensions of the keel that provide a cutout for either a centerboard or daggerboard to pass through. <strong>The</strong>y are also points of extreme high loading, and it is very common for damage and leaking to occur in these areas of the boat. Because of this, you should carefully build up the keel in the area in which you install a case. To do this, you might make the keel much thicker at this point, using more cross-grain plywood laminations to provide added resistance to splitting. Because a vast majority of the loading on a case is generated in the front where the slot protrudes through the keel, this area can become one of the highest load points in the entire boat structure. <strong>The</strong>refore, you should make the front of the slot especially strong to distribute this load over as much area as possible. Figure 19-10 illustrates our technique for building and installing centerboard and daggerboard cases. Begin by cutting a slot in the keel a little larger than the perimeter of the case. Lightly bevel the slot, shaping it into a wedge that tapers from a slightly wider top to a narrower bottom. Insert the case into the cutout so that it is flush with the bottom of the keel, plumb, and lined up with the centerline. Next, you must make sure that any epoxy you apply will not drip immediately out of the keel/case joint. Block the bottom of the case with a piece of wood or tack a bead of epoxy along the joint line and allow it to cure. We usually wrap thin plywood in plastic and staple it to the keel, as shown in Figure 19-10, and find that this not only prevents oozing but also helps to hold the case in place. Because the plywood is wrapped in plastic, it’s easy to remove when the joint has cured. When the anti-drip device is positioned, pour an epoxy mixture, slightly thickened with 404 High-Density Filler, around the outer edges of the case to the full thickness of the keel. Allow this to cure. To finish the case, apply a cap and round over its edges. Fiberglass cloth can be added as desired. We recommend that you apply it to the corners where the boat and the case meet. <strong>The</strong> method will result in a perfect structural fit between the case and the keel, and this will effectively transfer all loads to the keel. <strong>The</strong> chances of failure of the joint between the case and the keel have been minimized, so the possibility that the boat will leak when it is in the water is greatly reduced.
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Gougeon Br
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iv Table of Content Getting Started
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vi Table of Content Chapter 17 Mold
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viii Table of Content Later Product
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x Preface The brie
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xii Table of Content
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2 Introduction With the help of fri
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4 Introduction
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Modern Wood/Epoxy Composite Boatbui
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Chapter 2 - Modern Wood/Epoxy Compo
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Wood as a Structural Material CHAPT
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Chapter 3 - Wood as a Structural Ma
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WEST SYSTEM ® Products This chapte
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Chapter 4 - WEST SYSTEM ® Products
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Hull Construction Techniques— An
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Chapter 5 - Hull Construction Techn
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Getting Started Chapter 6 Before Yo
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46 Getting Started Finally, should
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48 Getting Started Designers’ fee
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50 Getting Started
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52 Getting Started Material Price/b
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54 Getting Started between layers o
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56 Getting Started mast; sails and
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58 Getting Started
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60 Getting Started and it is import
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62 Getting Started necessity. We al
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64 Getting Started Grit refers to t
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66 Getting Started An efficient flo
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68 Getting Started Ridge Pole Frame
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70 Getting Started
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72 Getting Started unimproved lumbe
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74 Getting Started If it is not yet
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76 Getting Started chapters, we adv
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78 Getting Started
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80 Getting Started The</str
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82 Getting Started cures quickly to
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84 Getting Started Evap. Rate LEL2
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86 Getting Started 4. Use wet, rath
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88 Getting Started
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Laminating and Bonding Techniques <
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Chapter 11 - Laminating and Bonding
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Scarfing Scarfing remains an essent
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Chapter 12 - Scarfing 109 and used
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Chapter 12 - Scarfing 111 Productio
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Chapter 12 - Scarfing 113 Figure 12
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Chapter 12 - Scarfing 115 Figure 12
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Chapter 12 - Scarfing 117 bevels on
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Synthetic Fibers and WEST SYSTEM ®
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Chapter 13 - Synthetic Fibers and W
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Hardware Bonding As stated earlier
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Coating and Finishing Broadly, the
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Chapter 15 - Coating and Finishing
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Strip Plank Laminated Veneer and St
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Chapter 23 - Strip Plank Laminated
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Hard Chine Plywood Construction A s
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Compounded Plywood Construction Mos
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Later Production Steps Chapter 26 I
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Review of Basic Techniques for Usin
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Selected Bibliography While the fol
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