A big, big, glueup

The outer keel/skeg/deadwood assembly is truly massive.  Once glued up and faired on two sawhorses beside the hull, I needed to figure out how to get it back up onto the hull, and in position to glue. It weighs about twice what it did when I lifted it last time. I wanted do the installation a a two step process.  First, I would hoist the assembly up above the hull, and suspend it there so I could apply  glue.  Then I would lower it into position before clamping it in place.

Clearly, this was not  a job for one old guy, nor even one old guy and wife.  Besides, my wife has been the victim of too many "Here, dear... just hold this for me for a minute  while I..." projects over the past 4+ decades to fall for this one, even if I had tried it (which I did not.)

Fortunately, I have learned to plan ahead, and I actually do so on occasion.  I acquired bought a pair of inexpensive 4 sheave block and tackle rigs off Amazon.com, fastened one each to the roof rafters above the intended forward and aft end of the assembly, and put a 1/4 inch screw eye at either end of the bottom edge of the assembly itself, hooking a block and tackle to each of them.  Then, it was just a matter of an easy lift, my wife at one end, and me at the other, to get the assembly into place.  I tied off the block and tackle ropes to the strongback, with the assembly suspended securely about half a foot above its final resting place.

 

I then applied a coat of unthickened epoxy to both surfaces with a roller, followed by a heavy coat of thickened epoxy to the lower surface of the keelson.  Finally, I lowered the assembly so it rested on the glue, positioned it carefully, and clamped it with a couple of clamps through the centerboard slot, and belt clamps hooked over the sheer plank at strategic points until I got squeeze-out.  

The skeg assembly glued in position, awaiting the lead ballast

 Cleaning up squeeze-out was done with a heat gun and paint scraper.  Smart people convinced me to wear a respirator, although I have frequently pointed out that it is too late for a slow-growing respiratory disease to get me if it hasn't already planted its seed.  Bruce Mackenzie says the volatilized glue is actually mustard gas, and I don't want to find out if he is mistaken or kidding.

Rudder mounting board in position for a trial fitting

My next step will be fitting the aft part of the skeg, a 2 inch wide by 6 inch mahogany board that is scarphed to the outer stern.  I test mounted my rudder pattern to it, and amazingly, it is pretty close!  Mechanical fastening comes next:  long screws and through bolts at the stern, and through bolts along the centerline at each frame.