In this week's episode of Onboard Lifestyle we work with honeycomb structural panels on our custom 435 catamaran SV basik. This project is one of many inside...

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welcome back to SD basic as you can see

by the smile my face I'm enjoying the

nice weather

a couple more days of this and then back

to the old rain and wind it's coming so

let's take advantage of this last week

we started prepping the sugar scoops

getting ready for the steering to go in

a lot of work needs to go behind the

scenes a lot of preparation needs to

happen inside there I've got a good jump

on it last week but we're gonna continue

this week and start filling in some of

the gaps there so let's get going

got a lot to do looks like the pond see

a little sanding session and start the

next little bit of work in here first

ice and

so this is a little bit of a mess well

teal is standing out the other inside of

the sugar scoops I am going to help him

by clearing out this side so that we can

start prepping on here

all this left is the anchor and another

box I've already pulled out all the

fishing gear crab pots wires tarps and

just trying to get an idea of what is in

here we gotta start getting more

organized

it looks like we got links belts filters

or filters

filters

some wire services

and looks like an extra pump

haha

these are keys to the engine that has

been missing for over a month

he'll swore that it's on the boat

somewhere and I didn't believe him

because he couldn't remember where it's

at which is really strange

that's not like him to forget keys and

where they're at but I think they he'll

be really excited that I found

where did you find us where do you think

I've no clue oh thank god I was gonna

order some new ones

it was Abel doll your field filters and

belts and pumps really why would it be

in there that's not like you well I'm

glad you found that what are you trying

to embarrass me yeah well thank you so

much this was actually really that made

my day next thing I want to do is run

some glass over this surface and and

that will tab it to the wall right over

my epoxy fairing here it'll tab over the

seam up the wall up this wall and I'm

not going to tap it over this onto this

surface yet I'll wait I get this

structure built and continuous pieces

will come over and tie this whole thing

together

I do need access to it though so I will

be putting affection

hatch in here it'll fit right about here

and I need a good size inspection edge

because there's a linkage mounted right

in here and I need to be able to get my

arms in and make adjustments or do

maintenance but mostly to get it all

installed

this wall is getting made with honeycomb

composite it'll fit right in here flush

with this but I this is raw I do need to

glass and snapping and cut this next

because I could glass this and glass

this at the same time save on rollers

and gloves and plate some bowls and all

the things you need to do glass work

after this is all glass tin I will cut

this inspection edge and that will be

the cutout right there this is a

template I've used that same inspection

hatch a couple times made a template

years ago cap it I'll use this again I'm

sure so let's get going on forming this

piece of honeycomb so I can start

glassing it in

shutting NIDA core or Kanak or any one

of these polypropylene honeycomb it's

easy when it's raw it's just tough just

lightweight and this is just Alice right

here you just need a good sharp knife

let's give a little score right on my

mark

and then try to plunge all the way

through next your played perpendicular

to the work there it is missed a few

fibers right here look I'll clean that

cuts okay there's my first smart now

I'll lay out the rest

okay I have whittled my honeycomb head

let's see how it fits that looks good

and then I made this funny little piece

what's it go right over here and that's

to continue this raised lip so I have a

nice shelf up here I'll still laminate a

three-quarter inch bull nose up here out

of probably that foam-filled PVC and

bring cloth up and over tied it into the

upper deck over this and tie it down

here but I wanted to get this all cut

out first so I could get layers of cloth

on both sides going at least two layers

on on the inside and the outside right

now and then more once I start

laminating this in so let's get going on

the epoxy into this okay back in here

I'm ready to lay my first layer cloth

down here nice and clean here's the

cloth I've got my baby wipes a roller

scissors and epoxy it's wet system and I

used a 205 hardener it's a fast harder

with a little bit of white pigment in

there just so I could see it rolling out

a little easier

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a tight quarters getting us in here

I will manage

taking clothes here just give it a

couple tugs want to get it as close as I

can before it start rolling

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usually lay down much faster than this

but kind of jamming us into a corner

here

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is take a look at this first layers in

I'm gonna let that fire off and we'll

put two more layers in but let's move

out and put that layer of glass on this

panel here's that piece of honeycomb

that I carved out just be much easier

than the piece I just laid down in there

it's all out in the open so I've stood

that butter this up fold my cloth onto

it and make sure it's saturated

now just roll out a nice even coat

and this one will be done for today

okay let's take a look at this now cloth

is all saturated and laid down nicely

you're gonna see a little bit of a

stipple from that honeycomb but each

layer I'll sand it before I put the next

layer on sand it put the next layer on

by then three layers you don't see it at

all but I'm happy with this first layer

here I'll trim all this off in the

morning

test fit it make sure everything laid up

correctly flip it over and put two

layers on the backside for tomorrow then

back in the hole god still loving this

weather

look at that

I'm gonna call it for tonight

take it easy

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good morning another beautiful day

that means we're gonna take advantage of

more epoxy work here's a piece that laid

up last night it is cured so I'm gonna

trim off all this glass I ran wild and

then lightly sand that edge in

test-fitting down in the hole

I put that piece in last night as well

we'll trim that up and just kind of see

where everything stands that will flip

this and get some glass on the other

side

okay come off nice and smooth so far

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okay I'll sand it up I didn't say on the

face yet I'm gonna do that at the end

but the edges are all prepped and ready

for me to test fit this I just realize

my piece is starting to resemble the

state of Oklahoma huh okay well let's go

see how she fits came back down the

sugar scoop here's that piece of

honeycomb I laid in I laminated some

glass on here tabbing it into the wall

into the bulkhead here over into the

hole I'm just kind of trying it all in

all so tap it over the same here I still

probably two more layers going on this

but it's a good start let's get this

trimmed off right now they ended up and

see if Oklahoma fits

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okay nice and smooth hey not too shabby

nice even reveals everywhere just enough

to get my dick and epoxy in there

I'll fare this in with a 1 inch radius

put a bull nose on the top and a sweep

glass cloth over this whole thing but

first what's loose let's get a couple

layers on the backside much easier to

work what's out that way I could get

another layer in here today too so much

to do behind the scenes here but it's

got to be done morning guys

we are on a supply run to fisheries

because we're running a little on

everything so

good morning Emma running and you know

that you're a boater if you use your car

as storage for your runners until you

get to that next budget yes they'll be

there another couple days sorry about

that

I know Emma's gonna have to squeeze over

to one side like she's getting used to

it

they've been in here and we're here

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I think already

get to work

Aaron

much easier to block that the drive in

this truck

wait wait

wait wait

wait

wait

now it's just a matter of doing that

same process over and over flipping the

work back and forth we try to get two

layers on this one today I don't like to

put a lot of layers on one side and then

flip it and put a lot of layers inside

it tends to take this honeycomb and

start to bend it by doing one layer at a

time look keep it fairly flat

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looks like this is our laugh nice

morning in a while

rains coming again so I better take

advantage of it

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kid is cured overnight cured nicely

let's trim this up

and now that I've hand sanded the

perimeter I'm gonna give the orbital a

nice passing on both sides flatten this

thing out so it's staying pretty good by

doing one layer on each side look at

this

just sit down this don't flap the work

stay nice and flat no bows no cups and

that's difficult when you have this like

this long arm sticking out so let's

stand her up

okay sanded nice and smooth

look at this I have a layers class now

we've been a 10-ounce cloth on each side

I don't need a lot of strength on this

it's just a an interior panel it's

trying to make it waterproof and a

little durable this weighs nothing these

honeycomb structural panels I mean it's

crazy the weight just drink Rachel I

mean one layer and I could barely get

deflection out of this get a couple more

layers on there it's amazing actually if

you want to check out a good YouTube

channel check out sailing Lady Africa

they are doing a refit on an older Dean

catamaran in South Africa and they use

quite a bit of night accord in their

process and it's a fun channel to follow

check them out

okay I'm not gonna bore you with the

additional layers I'm gonna be putting

on this I still have a couple layers

left but I've got plenty other things to

show you so let's get going okay back in

the sugar scoop here's my panel I now

have two layers of glass on both sides

it's time to start fitting this in

permanently but before I do that by

playing this out and put it exactly

where it needs to go play this out with

this wall

just like that

let's take a look at this I have an

issue there's still a gap behind this

about 7/16 of an inch so I'm gonna fill

that in next actually you don't laminate

it to my panel so when I epoxy this in

this gap will be already filled then

I'll be able to lay glass cloth when I

lay it over this deck up over the bowl

nose and down this wall they'll tie it

all together

still let's work on that next okay for

my little spacer I needs this PVC lumber

this stuff I use over wood any chance I

get I don't put any wood on the exterior

this boat a little bit on the interior

but for the most part we're using some

all synthetics we save a lot of weight

to this is very light compared to wood

so I've laid out my little spacer here

now it's just a matter of cutting it out

and laminating it in

there we go 7/16 that's a nice cut

huh

I just mixed up one pump of epoxy one

pump of 205 hardener and a little

colloidal silica to thicken it up I'm

just gonna put a little thin layer on

here get this laminated on so I could

put this in tomorrow

I just clean it up with my baby wipes

one little spacer is epoxy dan I didn't

want to put clamps on top of this I

didn't want to squeeze all the epoxy up

but just put a couple clamps on there

just hold it nice and straight well it

cures that'll be cured by morning

where there's a little gloomy or today

it's been raining off and on but it's

not raining right now so let's get some

work done here's that piece of PVC I

laminate on yesterday it's cured it's on

that for good and I wanted to talk a

little bit about the end grain and how I

treat it there's a couple ways to do it

you could fill it or I could take a

little piece of this PVC like I did

right here and just laminate the top I

did this last night so it cure enough

for today

and this works just like wood now I

could now that I have a little piece on

here hi kid

trim it I could shape it I could sand it

so I'm gonna put a nice quarter inch

roundover on either side that way when I

like glass up and over this it comes

around it nicely so let's put a bull

nose on this well not quite a bull nose

but at least a quarter is round over

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let's get this thing a fox eat in place

they do good everything settle down okay

let's take a look at this now before I

get this a box it in

I think Plains out nicely everything

fits in with nice reveal I took this

ingrained and just crushed it back about

a quarter-inch I've got this nice radius

on the top now now the glass will be

able to wrap right around that nice and

cleanly

of course it starts to rain so I've got

the hatch mostly closed need a little

light in here I've buttered up for the

perimeter here buttered up all the

perimeters here kind of cramped in here

but you can see I've got epoxy on all

the edges I'm gonna set it in place

really carefully here

I'm tight in here now but let's start

working this panel in

okay I don't want to get too much going

in here right now I've basically

laminated this whole thing in I've

worked this face here this edge here and

this edge here I'm gonna let that fire

off then I'll be able to work this back

edge and the side edge is over here I

just have enough going on right now I'll

be just making more of a mess as I go so

let's lift this cake and I'll come back

and finish this off I'm not gonna lie

that was a little tough getting that

piece in in this cramped quarters with

epoxy everywhere and it started to rain

right as I was setting it just a little

downpour just wait for this little

squall to go by so I could open up the

hatch so I could get out without getting

too much of a water on here suppose I

could just hang out here till it kicks

okay looks beautiful now but it's been

just dumping out here for two days

straight

gave it time for that epoxy to cure

let's a dry off this scoop open her up

and see it looks like

okay let's take a look at this news

panel it's a hundred percent epoxy-dent

nice and waterproof

when it's radius all the way around

it's ready for glass cloth that's gonna

come over this deck up over this and

then tie it all down into this bulkhead

here that I'll be able to fare and sand

it and paint this whole Locker will cut

her our access hatch in that we can

start get the linkage going in here but

I mean there's quite a bit of work still

left in there and a ton on the other

side so that's gonna have to have wait

see an exiting

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every week this year she is getting

better and better anyways guys it's like

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