sunfish wood parts restoration (by Epoxyworks)

I got my latest copy of “Epoxyworks” magazine in the mail earlier this week and was excited to see they had an article about the restoration of wooden Sunfish parts – the rudder, tiller, and daggerboard.  I completed similar repairs and improvements to my various Sunfish (and Super Porpoise) wooden parts as well, using more or less the same steps – but with maybe slightly more serious structural repairs for my gear.

photo by Epoxyworks magazine

you can read the full article here: http://epoxyworks.com/index.php/sunfish-wood-restoration/

JD summer clearance sale

I’m a big fan of Jamestown Distributors, and have been on their email list for quite some time.  today’s email had a nice little photo surprise – an old wooden Sunfish!

for Sunfish sailors, Jamestown Distributors is an excellent source for epoxy & fiberglass supplies for when it comes time to make repairs to your Sunfish hull.  they supply West System epoxy  & all the various fillers, and they have recently started their own line of boat repair products, the “Total Boat” line.  I also used JD to purchase supplies for when I did the repairs and re-finished my Sunfish daggerboards and rudders.

Sunfish hull repair method

here is an excellent video created by Shoreline Sailboats on Sunfish hull repair.  Shoreline Sailboats is an authorized Laser Performance dealer in western New York.

as an aside… it is nice to see Shoreline using the Total Boat product line from Jamestown Distributors.  I’ve purchased some of the Total Boat Thixo, but have not used it yet.  the Total Boat product line seems like a good alternative to West System products that is perhaps a little easier on the wallet!

sailing supplies

I was trying to organize my basement shop, and had my sailing supplies in 3 or 4 different boxes.  I decided to organize them a little better, but before I did that – I laid most of it all out on one of my workbenches.

there is a little bit of everything there: an old rudder head that needs to be cleaned up.  a pair of old tiller straps that have been polished up to look almost like new. a new tiller extension (a Ronstan Battlestick). bailers, old and new.  sail rings, old and new.  inspection ports. new lines – a mainsheet, halyard, outhaul and cunningham.  cleats – cam and clam. two options for Sunfish mainsheet control – a new ratchet block and an old swiveling fairlead and cleat. eyestraps, standup springs, hiking straps.  Interlux varnish, West System epoxy stuff, and the remains of my 2-part expanding foam (use to reset my foam blocks).

anything else I should add to my collection?

 

Norm Abrams builds a Clancy sailboat

I just found this 2-part series that Norm Abrams did for his show New Yankee Workshop where he builds a plywood and epoxy sailboat.  Norm first visits the Center for Wooden Boats in Seattle, Washington to talk with Bob Pickett, the builder/developer of the sailboat Norm plans to build – the Clancy.

the Clancy sailboat is built using marine grade plywood and 2-part epoxy.  Norm doesn’t ever mention the brand of epoxy, but it sure looks like WEST System epoxy.  the joints in the plywood are covered with fiberglass tape, and epoxied into place to create a strong joint that is also water-tight.

several coats of epoxy are also used to cover the entire wooden surface to again seal up the wood and make the boat water-tight.  as the epoxy is not very resistant to UV light, the bottom is painted with marine grade paint, and the sides and deck of the boat are varnished to provide a protective layer.

part 1 of the series (these are not very high-quality videos – if you plan to build one, I’d buy the DVD and plan set from New Yankee Workshop):

and part 2:

Duckworks Magazine has a great page on building a Clancy sailboat as well with several pictures of the process.

measured drawings for the Clancy sailboat are available from the New Yankee Workshop website, and you can also purchase a DVD with both episodes of the show.

I’ve always loved watching Norm on New Yankee Workshop, and woodworking has been a hobby of mine for a while.  I’ve been pretty happy with my Sunfish sailboats, but it might be a fun project to combine the love of woodworking and sailing into one project to work on over a long Michigan winter.

sunfish rudder and daggerboard repair – progress

a long while back I posted about refinishing my Sunfish and Super Porpoise rudders and daggerboards.  I proceeded to sand down a bit of the finish on the Super Porpoise parts, but sailing seasons got in the way, along with various other winter woodworking projects, and I never got back to finishing them, or even starting on the Sunfish wood parts.

so this winter, I bit the bullet and plunged full bore into refinishing the wood parts from all (3) of my boats – (2) Sunfish and (1) Super Porpoise.  here is a look at the (2) Sunfish rudders.

the lower rudder is from my new(er) 2000 Sunfish, the upper rudder is from my 1960’s Sunfish.  strangely the older rudder seems to be in quite a bit better shape, and the newer rudder appears to have some type of finish glooped onto it, some sloppily gumming up the rudder spring as well.

step 1 was removing the hardware and inspecting the condition of each piece.  the older rudder has a couple cracks up near the head, and the drilled holes for the rudder pins are all misshapen from years of use.

the newer rudder is in similar condition at the rudder pin holes, with no noticeable cracks.  but the finish that was used is all gummed up and just looks horrible.  pretty severe were is noticeable at the one rudder pin hole.

the daggerboard from the newer Sunfish was coated with the same finish, and was likewise a sloppy mess.  step 2 would be to strip the finish from the wooden parts.  since I would be working in my make-shift woodshop in my basement, I opted for the Citristrip (“safer”) Paint & Varnish Gel.  after brushing the orange stripping agent on and letting it sit for a while, I then used various scrapers to remove the finish.

the Citristrip gel worked pretty well for the older wooden parts, but the (2) newer pieces with the strange finish were hardly phased by it.  I hit them with a 2nd coat, and let is sit and soak longer, but it didn’t work much better the 2nd time around.  after consulting with some a Sunfish expert (thanks Alan!), I think we determined that the sloppy finish was some type of epoxy, which made it that much more difficult to remove.

step 3 was thus my process to get each board to a stripped and ready-to-finish condition.  I used my random orbit sander, and worked my way through several grits, carefully starting with 40 grit.  normally, I wouldn’t use 40 grit, as it is quite rough, and even then I only used it for the flat portions, but extreme measures were required to get through that sloppy epoxy. 

I then would work my way up to 60, 80, 100, and 120 grit papers, and by then the boards felt pretty smooth.  I used a bit of 60 grit paper by hand on the edges, and then jumped right up to 150 grit to finish out smoothing the edges.  during the power-sanding, I wore a sanding mask, and had my large shop dust collector running right near the workpiece, as well as my air cleaner that is hanging from the floor joists to help keep dust down as much as possible.  every once in a while, I would empty the small bag that collects sanding sawdust on the random orbit sandpaper into a plastic jug – as I will be re-using some of the sawdust later for repairs.

I didn’t try to sand out some of the deep gouges, as you can see above, but will use a filler later on those areas.  some of the leading and trailing edges of the boards had some dry rot that I removed as best I could.  I used a block plane to slightly re-shape the daggerboard edges by hand.

step 4 is various repairs.  the upper ends of the daggerboard have holes of various shapes and sizes from the hardware that had kept the handle in place.  some were just stripped nail holes, some were bolt holes that had pulled right out of the board end grain.

I used some blue painter’s tape to dam off the end, as well as to close of the bottom of the board.  I then mixed up a batch of West System epoxy (I buy mine at Jamestown Distributors or US Composites).  I have the 105 resin and 206 slow hardener as shown above.  to this I mixed in some of the 404 high-density adhesive filler (white in color), and I added in some of the saved sawdust (in the plastic container on the left in the picture above) to get the epoxy mixture colored similar to the wood.

this picture is the end result – from the side the blue tape was on.  the other side needs to be sanded and smoothed down some as I didn’t apply the epoxy perfectly level.  but I was impressed at how well the simple blue painter’s tape worked on the bottom and end grain areas.  I will probably use this same mixture to fill in the out of round holes in the rudder heads, and just re-drill new holes after the epoxy has hardened.

for the cracked sections, I am going to try to reinforce the cracked area by drilling a hole and inserting a dowel, set in place with some epoxy.  I cut a small notch in my Super Porpoise rudder to create a flat area to start drilling.  I’m sure it would help immensely to have a drill press, or create some sort of jig – but I don’t have either, so I just free-hand drilled the 1/4″ diameter hole.  I had bought an 18″ long drill bit at the hardware store that worked well. for the dowel – I am using a stainless steel piece of 1/4″ diameter threaded rod, cut to length after I’ve drilled the hole.  it is shown below, only partially inserted into the drilled hole.  it won’t be visible after I’ve filled the hole with epoxy.

again, I just mixed up some of the West System epoxy (which with the metered pumps is a breeze to get the ratios correct).  this time I didn’t add any filler (although I probably could have used the 404 for added strength), and used the dowel to insert as much as I could down into the drilled hole before placing the threaded rod in there for good.  I will use this same repair on the cracked Sunfish rudder head.

with the remainder of the epoxy I had mixed up, I added some 407 low-density fairing filler (the 404 sets up really hard and is difficult to sand, the 407 is softer and easier to sand into a nice finish).  the 407 filler is already a brown color, but I think I added some sawdust anyway.  I then just applied this to various small gouges and nicks on the various rudders and daggerboards to fill any spots as required.

after this has dried and hardened, I will sand the patched areas smooth, and do a final check on each board before the finishing process can begin.

I still have some work to do (dowels in the Sunfish rudder head, epoxy the Sunfish rudder pin holes to then re-drill, etc), but progress has been made.  now the weather has been crazy warm in Michigan this late winter(?) and early spring, so I’ve got to get in high gear to make sure the parts are ready for sailing as soon as possible.