Thursday, April 23, 2009

Frame end progress

Work has stopped on scarfing the frame ends. We have installed the laminated ends which were completed, but now we have no more glue.
The only glue I know of that is really satisfactory is the Aerodux-500, and yet that seems not to be available. As of Tuesday afternoon, the distributor in California admitted that he did not have it in hand.
We sought alternatives. We made up sets of laminations using epoxy, Weldwood resorcinol clamped lightly,and Weldwood clamped tightly. We then broke them using a weight suspended below a fork lift. We also broke a sample of the Aerodux which had been cut off of frame scarfs.
The Weldwood failed completely. The glue itself split apart, indicating its cohesion failed rather than its adhesion to the oak slats. DAP system engineers promised an investigation, if we would send them our lamination and glue batch.
The epoxy was very strong; the glue sucessfully adhered, until the slats themselves split apart. We would use epoxy, except for the folklore we have heard, which says that West system epoxy does not adhere to oak.
The Aerodux scrap also broke by wood fiber failure, rather than by failure of adhesion or cohesion. In view of the poor reputation that epoxy has with oak, I am planning to wait for the Aerodux.
Work therefore has begun on reinstalling the rudder. Fitting it in place, using the replacement shaft, showed that we need a little more trimming on the dutchman at the top of the stern post, and I am doing that. When that fits, we will install the bottom bearing.
Roger is shaping the false keel timber, using his favorite adze. It should be done quickly.
We discussed the false keel liner. Its failure was due to delignification of the wood next to the bronze liner, and excessive wear at the bottom opening for the centerboard. The bronze liner was not reusable, and a replica would have been awkward and unsatisfactory to install. Instead, the present plan is to line the false keel with G-10 FRP, and install a UMHWP (ultra-high molecular weight polyethyline) replaceable wear insert on both sides of the bottom opening, to carry the side load of the centerboard. We will attach the G-10 with West System G-Flex, which is designed for gluing plastic to wet wood. The UMHWP, formed into a 1" by 2" bar, will be attached behind the bronze worm shield with wood screws. All the parts have been ordered.

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