BananaShark plug, mould and boat build

Cookee · 08 November 2005, 16:01

We took some photos of the build of the plug and moulds being made for our leisure boat, just thought it might interest some people as to how things are done now summer has drawn to an end!

The photos are from a fixed point in the workshop, there is a GIF that I'll try and get hosted so that you can see the progress in a time delay sort of fashio as well! (Have a look and see if you can see the shark hanging from the ceiling - he spins around from time to time!)

The details of the new boat should be on the website in the not too distant future - meanwhile if anyone would like details we have a shiny brochure and of course a demonstrator down here in Devon!

The first three are of the hull plug on the right, the race boat moulds are on the left, and the foredeck and console mould and plug is in the centre of the photo along with our scooter!

This shows the mould and plug having been removed from the foredeck, then seperated, then the plug being rplaced on the hull plug so that it all matches up later on ...........

Cookee · 08 November 2005, 16:12

Here Kitten is making formica panels for the flat surfaces, these are glued in place using contact adhesive and then nonslip on top of that where nesesary.

An engine (225 Optimax) has appeared by the roller shutter door in the meantime!

Cookee · 08 November 2005, 16:20

A bit of a move around in this sequence!

More of the formica has been done - as well as some that you can't see - the base must be compeltely flat - we got through a lot of body filler, foam, wood, screws and glue making the plug!

In the second shot the raceboat mould has moved and the foredeck mould is now in the centre foreground, this is a split mould and the rest of it which is the console / dashboard part of it is beside it on the floor.

Third one shows we have made a bit more space and more formica is cut up ready to go in.

Cookee · 08 November 2005, 16:26

In the meantime Kittens Panther moterbike has appeared, the rear seat has been shaped more as well as the base for the a A frame. The plug for the console is in the centre by the bike, and the engine has moved!

Trying out the room we have for the engine to tilt into using a cardboard cutout.

Cookee · 08 November 2005, 16:29

The A frame takes shape - that's Stainless Dave holding it up in the first shot!

You can see the cardboard cutout of the engine in the last one - showing we have plenty of clearance.

Cookee · 08 November 2005, 16:34

The cockpit and locker flooring is coming along well and the back seat, A frame support, fuel filler area and rear deck all get developed in this sequence.

Cookee · 08 November 2005, 16:39

You can see the different areas on the rear deck - white for the smooth formica, and the light blue which is the nonslip material after it has been paited with PVA and a blue dye (so you can see where you've painted on a white surface). The shape of the engine well is finalised as is the cockpit floor area.

Cookee · 08 November 2005, 16:44

PVA'ing under a tunnel to keep out the dust and aid drying - you can see the flange at the transom - this is where the rear deck part of the mould finishes and the transom / hull starts.

Kitten starting the gel coat for the mould - green is used because you don't get many green boats (they're meant to be unlucky), and it is easier to see through if you've missed a bit when you're gelcoating a mould.

Cookee · 08 November 2005, 16:45

More gelcoat!

Cookee · 08 November 2005, 16:46

That's the gelcoat done!

Cookee · 08 November 2005, 16:49

Time for some matt now - and a visit from the neighbours!

Cookee · 08 November 2005, 16:52

Some balsa to strengthen the flat panels and then some ply to stiffen the whole structure.

Cookee · 08 November 2005, 16:57

Making the ply stiffening is a bit like doing a puzzle - lots of different shapes that interconnect and together make a strong stiff mould that will last - miss parts out or design it badly and the mould won't last and will not give a faithfull reproduction of the plug.

Cookee · 08 November 2005, 16:58

More ply - you can see the structure building up.

Cookee · 08 November 2005, 17:04

The "tray" mould, which consists of the rear deck, rear seat, cockpit floor and forward locker floor and bulkhead, has been stiffened and we can start on the hull now - this is an old race boat hull that we have to make perfect again.

We'll lift it up, spin it over and put it down again!

Cookee · 08 November 2005, 17:06

There she goes!

Cookee · 08 November 2005, 17:07

This is one thing that dropping isn't an option!

jwalker · 08 November 2005, 17:09

A good sequence Cookee. Is the deck plug finished to a final surface or did you work the surface of the mould after it was removed?

Edit: oops sorry, I didn't realise you hadn't finished posting.

Cookee · 08 November 2005, 17:10

Let it down nice and gently!

Now to start work on the hull .............

The Jackeens · 08 November 2005, 17:25

Very interesting Build Blog.

Should it be a 'Feature' ?

(Nice to see your workshop again Cooks

)

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