Frisco Flyer Sailboat Restoration Project

2011-11-12T17:45:00.001-05:00

2011-11-09T06:40:00.003-05:00

2011-11-09T06:40:00.001-05:00

2011-11-07T10:07:00.000-05:00

Sails are a mess....I couldn't care less. Just happy to be sailing.

2011-11-03T13:24:00.001-04:00

2011-10-29T14:33:00.002-04:00

Big storm tonite. Gusts of 55-60 depending on what side of the river you live on. The Maine side claims 60 mph gusts where I am moored. I'm the furthest outside the pack, the moat exposed to the NNE winds on a loaner mooring. I went out and stripped everything from the deck. The main, boom, cowls, boathook, extra lines etc were all taken in. Then I had the good luck to meet the guy that services most of the balls and gear. He told me where the 6000 lb block with brand new gear on it. I exchanged a bottle of wine to stay there tonight and until I'm hauled out. I will sleep much better tonight!.

2011-10-26T04:35:00.001-04:00

2011-10-25T06:31:00.001-04:00

2011-10-25T06:29:00.001-04:00

2011-10-25T05:26:00.001-04:00

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2011-10-05T13:34:00.003-04:00

Launch...

2011-10-05T12:54:00.002-04:00

Stepping Mast.....

2011-10-05T12:51:00.000-04:00

2011-10-02T13:42:00.001-04:00

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2011-10-01T16:00:00.005-04:00

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2011-10-01T16:00:00.003-04:00

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2011-10-01T16:00:00.001-04:00

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Driving the dinghy

2011-10-01T15:59:00.001-04:00

Maya's faces while trying to avoid hitting mooring balls, islands and boats. She did great!

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Dinghy school.....

2011-10-01T15:54:00.001-04:00

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blue tape...

2011-09-27T19:42:00.001-04:00

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blue sky.....

2011-09-27T19:41:00.001-04:00

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2011-09-26T19:00:00.001-04:00

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2011-09-19T07:03:00.001-04:00

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2011-09-19T07:01:00.001-04:00

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2011-09-19T06:57:00.001-04:00

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2011-09-19T06:56:00.003-04:00

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2011-09-19T06:55:00.001-04:00

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2011-09-11T23:10:00.001-04:00

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2011-09-11T23:05:00.001-04:00

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Couple more pictures of Yanmar going in....

2011-09-10T06:56:00.001-04:00

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Epifanes, Jap dryer and Fela.....coats 5 & 6

2011-09-09T06:06:00.001-04:00

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Yanmar ...

2011-09-09T00:09:00.003-04:00

With Steve's help, the Engine went up over the side of the boat and down onto the beds...looks like a good fit!

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Fela Kuti Midnite Mastness....

2011-09-08T07:57:00.004-04:00

I'm trying to wrap up all the loose ends as an eventual launch day gets closer,. One of the bigger projects still to finish is the mast. For the last couple evenings, between reading bedtime stories and tucking Maya in, I've been sneaking out to a friends barn to get some varnish on the mast/put the hardware on it etc.
The mast is on two sawhorses in a big empty barn. Theres no electricity inside but I have an extention cord to run a couple of lights attached to a ladder. The small lights arent enough to fill up the whole space but I can see the mast well enough to get some initial thin coats on. Even though the conditions are lousy, I love it. With the small lights casting huge shadows on the walls, the doors open to the darkness outside, the smell of the ocean, the sounds of owls and rain mixed with the Fela Kuti streaming off the internet makes for a great way to spend the evening (or even two or three of them).

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Finally picked up the rebuilt Yanmar..

2011-09-07T05:24:00.003-04:00

Went up to Maine to pick up the Yanmar. It was hanging from a small boom crane. I was able to get the car close enough to it where I could slowly lower it and nudge it into the back of the small Honda. At home, Maki and I eased it up and out (its only 145lbs dry weight so its not too heavy), slid it down a wood ramp onto the floor of the garage. As soon as there is a break in the rain, I'll be setting it in place on the beds to check the fit etc.

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2011-09-06T06:00:00.001-04:00

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Beds epoxied in place....

2011-09-05T23:06:00.002-04:00

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Beds...

2011-09-05T22:33:00.001-04:00

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2011-09-05T21:59:00.001-04:00

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Winches....

2011-09-05T21:51:00.001-04:00

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Rudder bolts...

2011-09-05T21:47:00.001-04:00

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Mast glue up ....

2011-09-05T20:35:00.004-04:00

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Bow cleats and some company.....

2011-09-05T20:28:00.001-04:00

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More mast...

2011-09-05T18:21:00.001-04:00

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Mast progress...

2011-09-05T18:14:00.001-04:00

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New bottom paint...(epaint)

2011-09-04T09:40:00.001-04:00

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Chainplates cut/drilled.....

2011-09-04T09:38:00.001-04:00

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2011-09-04T09:36:00.001-04:00

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2011-09-04T07:53:00.001-04:00

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Awlgrip for rudder....

2011-09-04T07:51:00.001-04:00

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More Toerail...

2011-09-04T07:38:00.001-04:00

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Toerail....

2011-09-04T07:28:00.001-04:00

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Rudder...

2011-09-04T07:25:00.001-04:00

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More rudder shots...

2011-09-04T07:23:00.001-04:00

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clean engine "room"..

2011-09-04T01:30:00.001-04:00

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Putting the rudder back together....

2011-09-04T01:28:00.001-04:00

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A couple shots from a trip to the Virgin Islands last winter..

2011-09-04T01:23:00.002-04:00

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2011-09-04T01:20:00.001-04:00

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2011-09-03T23:01:00.001-04:00

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New trim on cabinhouse....

2011-09-03T22:49:00.001-04:00

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New chainplates are on.....

2011-09-03T22:45:00.001-04:00

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More Yanmar....

2011-09-03T22:44:00.002-04:00

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Yanmar is ready and waiting...

2011-09-03T22:43:00.001-04:00

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Old beds are out....

2011-09-03T22:41:00.001-04:00

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new bedlogs.....

2011-09-03T22:34:00.001-04:00

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?

2011-09-03T21:06:00.001-04:00

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2011-08-24T17:27:00.003-04:00

Well, let's see....since the last post, there was a three week work stoppage on Jackaroe. We went hiking on the AT. It was a long overdue trip, albeit a brief victory for team Land in the epic "land vs sea" battle. We, our now 8 year old and red dog Ruby climbed 14 4000 fters and covered 55 miles. Strangely enough, I thought very little of the boat. I was ready for a break!
Now back home, I have just about everyth but to put the motor in and varnish the mast. Hope to post pictures soon and to launch within a couple weeks to make the most of the tail end,of the sailing season here in NH.

Lots of progress...

2011-05-03T17:26:00.005-04:00

There's been so more progress on the boat that I'm not sure where to start...The remaining big projects were the rudder, which was still in several pieces with huge chunks of iron corroding, expanding and twisting the wood, the mast (box construction)was still in two pieces, the bottom and sides were already epoxied together, the whole thing has been lined with carbon fiber and coated in epoxy but it needed to be wired and the top had to go on, then spreaders lights, sail track/hardware, varnish etc. All of the deck hardware needed to be installed, lights wired, motor well glassed in/tabbed, the chain plates were to be hung on the knees I made but after more than a few couple sleepless nights, I changed my mind and knew that they needed to be hung on the outside of the hull. All these things were completed since then and more. I've been taking pictures along the way but I have been working on project after project for months. The plan was to go in last week. I called and even had the local haulers ready to go. This really pushed me to get everything done and to focus on the more important issues with the boat and not to get caught up in the bronze polishing or tinkering with the head etc. (which I still seemed to get distracted by) The boat wasn't ready to go in because the motor still needs to go in, BUT everything else is done and by the time the motor is ready, so will all the other little things.
Besides the motor being out, the next big deal is the toe rail. Its still off, but ready to go on the next warm day as long as I have some help (For three years, I didn't ask for any help except from my always eager kid, but I'm learning to accept help from all my friends especially as the weather gets warmer and summer break gets closer!)

Lights on the boat...

2011-02-05T21:05:00.005-05:00

Since the Fall, not much has happened to the boat. From here on, the big things left are to do the final glue up on the mast, to finish the rudder, to put the toe rail on and to drop the motor in. When the holidays were here Maki suggested decorating the boat....

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2011-02-05T21:05:00.003-05:00

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2011-02-05T20:58:00.001-05:00

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Field trip to Maine....

2010-10-13T19:01:00.013-04:00

Back in April a couple of us went to a boat yard in Maine where we were hoping to pick up a few things for the fleet. The word was that there was a yard selling bits and pieces off of their older inventory and it was a kind of self serve situation. Go in, rummage around, grab what you want and agree on a price. We got there and there was some cool, old bronze bits and plenty of useful things. I was tempted to pick up these three inch bronze cowls because while I have the old Nicro cowls, I really want a nice pair of bronze ones. These bronze though were abut ten inches high and looked like a corn a copia.

In the end, I picked up a small portlight, a small bronze (yard made) snubbing winch, a small Merriman wich and two small bronze Merriman winch holders and a Merriman winch to fit ( I have one already that came with the boat).
My Box.......

What was cooler than the stuff on the inside was the stuff on the outside.

There was a lot of nice boats but the one that caught my eye was a small pilot sloop that someone was just finishing after six years of work.

Inside and out, this thing seems to have been built strong.

Beautiful boat...

New(er) Countertops.

2010-10-09T20:27:00.003-04:00

While I had made a stainless counter for the sink....I liked the idea of boat sides being wood... I made these with some scrap mahogany...

2010-10-05T21:45:00.001-04:00

Gold cove stripe....

2010-10-03T22:14:00.002-04:00

This weekend, it was sunny and cool and I painted the cove stripe/CL scroll gold. I used One shot sign painters gold paint. It took a really long time because I didn't tape it off (because it was recessed/routed into the hull) but it really needed a steady hand to make it look smooth/uniform. All in all, it looks great and I'm really glad to see the outside of this boat come to a finish.

( The new Awl Grip looks pretty good too.)

Prepping Hull for Awlgrip....

2010-09-27T06:02:00.003-04:00

Reinforcing/tabbing bulkheads....

2010-09-25T23:10:00.006-04:00

Back in May, I sanded, vacuumed, washed with solvent, then laid down some mat and cloth fiberglass. A couple layers on all the corners under the seating and cabinets. I wanted to paint these areas but thought it would be a good idea to reinforce them first.

After all the glass was in, sanded, vacuumed, wiped down with solvent, and finally given a couple of coats of Interlux one part poly. Now the hull will be sealed from water intrusion, inside and out!

Removing trim/molding around cabinhouse....

2010-09-25T17:50:00.002-04:00

While working on fixing some leaks in the cabin house roof, I found that some of the old fiberglass either didnt cover all the way down to the trim piece and was letting water in or it used to reach all the way but has since cracked and water has crept in. I decided the best thing to do was to take the molding off to make sure the seal around the cabin house roof were 100% all the way around. The pieces didn't come off easily, and I wish I saved those corner pieces!

Summer 2010 update....

2010-08-15T08:35:00.002-04:00

The boat is coming along and should get painted in the next week or so.
Hope to put her in this Fall.
Still need a motor.
Will put up pictures ASAP

Flyer III photo and drawing....

2010-05-10T22:41:00.002-04:00

I was able to get Flyer drawings from Cheoy Lee last year but I was only able to get a Type I drawing. Came across this Type III drawing and a great picture...

Sheerclamp nightmare….

2010-05-08T23:33:00.000-04:00

Sheerclamp nightmare….
I was checking my handywork on the starboard side sheerclamp and while the big piece of oak that I had put in last year was bomb proof, I did find a little more rot on both sides. I haven’t really decided how to handle this yet. Part of me wants to clean out all rotten bits from the inside before replacing it with new wood, all from the inside. The other idea I had which could be easier in some ways but more painful in others would be to open up two small holes in the bow and after cleaning out all the rot from the inside, I could slide in new pieces in from the bow openings and epoxy in place. Not quite sure on this one yet. I hate having to go back and do some of this stuff after the rest of the boat has come so far. We’ll see.

Cabin house…

2010-05-08T23:32:00.004-04:00

Along the same lines of crack repairs.. I wasn’t satified with the way I had decided to repair the cabin house. I had just planned on fixing any leaks in the roof but after taking of the trim pieces around the edges I wasn’t happy with the way it looked at all and was worried about water eventually working its way into there eventually. I started to think about sanding the whole thing and applying a thin hardwood veneer over it. Cut out the portlight openings, trim top and bottom and epoxy in place. The inside will stay as it is but hopefully with the outside completely covered in a new layer of wood and sealant, that too should be water tight for years to come…..

Green paint….

2010-05-08T23:32:00.002-04:00

Green paint….
Going back into the boat after a while and looking at the way the dust, dirt and little bits end up in all the little corners and creases under the seats and berths in the cabinhouse. I’m sure looks like this would only get worse once the boat was being used all the time. I wanted to have a different color than the white so I found an old can of one part epoxy paint. It was sea green, a left over from a half hull project my dad had worked on about 6 years ago or so. Opened the can, mixed it with a drill and gave all the lower areas a coat of green which should do a better job of hiding the dirt, grime and water stains etc.

Gouges in hull …

2010-05-08T23:29:00.004-04:00

Last year, I had cleaned out any large cracks in the gelcoat by scraping down into the gelcoat but not through into the fiberglass beneath. After that they were filled and I had been fairing them out along with any of the deeper dings and nicks that I found along the way. There were two or three small spots that needed to be cleaned out making sure to leave a nice text book West System 12-1 taper.

After spending a long time getting the hull back close to fair and close to painting, one afternoon I started to second guess the work I had done thinking that while it was pretty good it wasn’t as good as it could be. I started to think about water intrusion and those cracks being deeper than I really liked. Some were only through the gel coat but a lot were really all the way through or close to all the way through.

I grabbed and old style can opener, the one I had used last year (again, sage info from West System) and started to scrape the cracks open again but trying to go all the way through this time. Way too hard. I walked back into the shop (formally known as the garage) and grabbed a Dremel type tool. I put a carbide or diamond tip on it and in less than an hour, I had 200, 10 inch long, ¼ deep gouges…on each side. That seemed to work much better but the boat looked worse than ever.

The weather was good and dry so I didn’t have to fill them right away and I could sneak away to a friend’s for dinner with the girls. Later that evening, when we got back but before reading Maya a bedtime story, I mixed up a big batch of West system and micro balloons and filled them all up.

They sat that way for a few days and last night before the rainstorm, I was able to start sanding the excess off and hopefully tonight I’ll get to the other side and then finish filling them in.

After all this, the boat will look them same as it did a week ago, looking close to fair and close to painting but this time I know that these small cracks will never open up and let in any water. That doesn’t mean others won’t show up but if they do, it should only be a couple. Its funny, if I had a finished sailboat and found my hull looking like this one day, I would probably have a heart attack, but nothing seems to faze me these days with boat projects…hopefully they never will after all of this.

Tape removal...

2010-05-01T22:03:00.004-04:00

Maya has been dying to do something with me on the boat and I feel bad that I keep having to tell her that she cant help out because of either the chemicals or fiberglass. I wonder how different it would be if this was a wooden boat... if I was working with wood, pine tar etc, would she have more of an opportunity to work with me? Maybe, but for now shes being patient with the process. I put aside any deck or hull work so that she could be around. She went straight to work pulling up any of the old tape that was still down from last years high build primer.

Deck..

2010-05-01T21:55:00.003-04:00

Frisco Flyer trip blog...

2010-04-24T10:39:00.002-04:00

While looking of something else I came across this link to a trip blog and the boat is a Cheoy Lee Frisco Flyer named Sumatra....

http://sailing-sumatra.livejournal.com/

Cabin house leaks....

2010-04-15T09:06:00.004-04:00

There were two small leaks in thecabin house ceiling. when ever it rqained, there were two small trickles of water on the Port side that seemed to be coming in from the area where the fiberglass cloth on the roof meets the walls of the house. Covering that edge of fiberglass was a piece of molding. I took off a piece of the molding to look under neath and when I saw how there wasnt much of an edge to speak off and that the sealent that was used was spent and no longer keeping any water out.. I was suyrprised that I didnt have more leaks. So i ripped off teh rest of teh molding and decided that what I'll do is get some thin veneers/laminate and wrap the wall in this, bed that in some boat life or something, feather hat up against the fiberglass on the roof then add some glass on the roof and feather that over the "new walls".

After that, I'll repaint the roof and add a new piece of molding to cover that joint as well as the lower section where the walls meet the decking.

Some shots of the molding etc...

Lots of sanding before painting...

2010-04-15T08:59:00.005-04:00

Now that I'm done fiberglassing the deck, I have lots of sanding to do before I can ever paint it. I started sanding the micro balloons and epoxy yesterday and relized just how long this next part will take in order to get the deck perfectly fair and level.

It sands easily enough, its just that I cant always see the high/low spots until its all been sanded which makes me think that I'll be sanding until sometime in May.

Someshots of the deck and hull/deck joint.....

Jackstands....

2010-04-15T08:52:00.003-04:00

I havent moved the jackstandsfor a long time. As the weather has changed, they have settled into the ground. I've kept the boat level by adjusting them up or down, now it was time to move them out of place, replace the boards under them to support them and slide them back in...

So thats what I did. It can feel a little dangerous when ever I'm underthe boat dooing anything. there was one day when I had to work on the bottom of the keel and looking up it seemed as if the whole boat could come down on me in a second.

So far though...it hasnt happended yet...

Some pics..

More deck pictures..

2010-04-11T15:10:00.005-04:00

One more shot of the extra glass in the Winch area and on the rail

This is the first skim coat of epoxy and microballoons. Feels like it took forever to get to this point...

When this was all finally finished, I started to wonder if I had enough glass down on the 1/2 plywood decking. Was just one layer of glass all around, with another on the rails, bow etc? I spent the day stressing about this until I went to Steve's last night to help him slide in his 6 looong bilge stringers into Cicada. While there, I was looking at Cicada and talking to the guy that re did her deck 20 years ago or so and it was still going strong with one layer of glass over a 1/2 inch plywood deck. I feel better now. Cant wait to finish fairing the microbaloons and prep it for painting.......!

Small fingers...

2010-04-11T15:01:00.004-04:00

Maya hasn't been able to help much lately because of al the epoxy and fiberglass but she jumped at the chance to clean the old tape off of the cleats left over from varnishing the cockpit area. My fingers are too big for this job and she wanted to help do anything before I started working with all the toxic stuff again...

Deck progress...

2010-04-11T13:12:00.006-04:00

After a couple of rainy days there was another break of nice weather and I got a lot done on the decks. Once the last piece of glass was laid and cured, I sanded all the seams and gaps smooth, faired the edges as best I could to the hull, and did a overall all sanding to rough it up before putting on any more epoxy, then I put on a "skimcoat" mixture of epoxy and micro balloons on the deck and over the rail.

A shot of the rail after its second layer of cloth. I had about three inches on deck and two over the edge. The initial layer of cloth down had about three or four inches over the edge. This made sanding easier later.

This is a small extra section of glass where the winches are mounted. Steve gave me a small bit of Dynel. I had enough for the winch pads and the pulpit area..

The forward two thirds of the bow has an extra layer of Dynel and then there is the extra layer along the rails

When it was all sanded and wiped down, I had Maya take a couple pictures....

Fiberglass Deck....Finally!

2010-04-06T05:09:00.006-04:00

So when the forecast called for 4-5 days of sunny warm weather, I knew I had to get the fiberglass on the decks now in order to get everything else finished for her to go in. I wanted to just get started with the epoxy but once I was out there, about to spread out the cloth, I realized that I had to grind/scrap, sand a few inches of the hull in order to make a stronger bond between the hull and deck. The hull is covered in a thick gel coat (thick on the port side but thinner on Stbd. for some reason. Probably has to do with when they were building up the hull in the mold back in 1965. Its so clearly thicker on one side that I'm guessing that afterthey sprayed the gelcoat, and then the glass, that the boat rested on its port side and the gelcoat settled more on that side? All just a guess.) and getting that gelcoat off is not easy. The best way was to use a 3 innc grinder and if I was careful, I could feather and smooth it from gelcoat to raw fiberglass hull. If I was in a rush to get back in the house to read a bedtime story or to make dinner for the girls, I would grind it in a real choppy rough way that was harder to sand smooth before the glass and epoxy went on.

Some pictures from the last few warm days...

Glass cut and ready to go...

Three inches or so of the gelcoat was grinded, sanded and wiped clean...

The deck was sanded flush/fair one last time, the transition from deck to sides was sanded smooth and wiped down....

Glass waiting for epoxy...

The weather really cooperated, warm sunny and no wind on the coast for once. Once I had the cloth cut to the rough shape that I needed, I made sure there was enough to extend over the edge to bond to the hull. Then I would mix up 5 or 6 oz of West System epoxy, pour it along the cabin house first and drizzle the rest out on the rest. Once the epoxy had really soaked in and set along the cabin house, I "Squegeed" the rest out away from the house towards the sides. This seemed to work great and I have to say that I ended up being pretty good at this. On the whole deck, I have only found one small bubble that I must have missed. Once the epoxy had kicked off and was getting set, I cut the excess cloth and peeled it off.

A couple days later...... the deck is fiberglassed!!

Ok, whats still left is...

1. sand the deck
2. run glass tape along the edges, cabinhouse and pulpit area
3. epoxy those areas and sand fair
4. mix up PLENTY of epoxy and microballoons, spread, fair and sand
5. do this a couple more times
6. high build paint?? not sure if this is overkill
6. or 7. epoxy paint.
7. or 8. re install, deck hardware
Done.

stainless countertops...

2010-03-28T17:07:00.005-04:00

This weekend, I spent Saturday pouring still more epoxy and sanding the deck fair. It takes so long for it to cure in this weather! It looks pretty good to me at this point and it will probably be all set for fiberglass. I can still fair it some more later if I think needs it.

On Sunday, I set about working on the counter tops. I ended up calling around to see if anyone knew where I could get some 316 Stainless sheeting. Steve had some left over from a project and after a few hours of cutting and grinding, the sink and faucet look great with the stainless counter tops...They're just dry fitted at this point and the stainless still needs to be bedded to to the plywood base. When that's done, I'll trim them out with teak molding and I guess it'll be time to check the sink through hull before plumbing it.

I finished in a hurry because the weather was starting to turn for the worse and I wanted to get the boat closed up so I didn't take any pictures. Maya and I will take a look at it tomorrow after work/school.