Got everything cleaned up, filled in, and ready for glassing. Couldn’t get the 1/2″ radius on the butt block like I wanted because the router bit I have hangs down too far. I only was able to get the 3/8″ bit to fit in the space I had.
Pro Tip: round-over the butt-block before installing it. You will have a much easier time if you do that. The manual should mention this… and I should have thought ahead and done it even without the instruction. Even better would be to rip-cut the edge at a 45-degree angle and then sand down. You wouldn’t even need a fillet if you did that.
While I was filleting things, I also finished the cabin shelf fillet and glass. This is a good example of pre-wetting the fiberglass before application.
On to the last big fiberglass job. Lots of lessons to re-learn coming up in … 3 … 2 … 1 …
Ok… first lesson learned. I should have absolutely NOT done both sides at the same time. I have neither the experience or innate skill to do a quality job of it. It’s OK, but not half as good as it should be. I tried soooo hard to keep bubbles from forming at the butt block but I just couldn’t get them all out. With the two layers of cloth and insufficient radius on the block itself, I was doomed to failure. It would have been possible, I believe, if I had only one layer of cloth. Or a better radius.
Pro Tip: Do one side. Let it cure for a few hours. Then do the other side. Especially if your butt-block isn’t as rounded as it should be.
Second lesson is to keep the cut edge of your cloth near the butt-block, as they show in the manual, not overhanging the side like I did. If you have it overhanging like me, forget about the tape. The cut edge loves to fray and come apart (as you know) and removing the tape from under the saturated cloth makes a sticky, stringy nightmare you’ll be chasing with scissors. You need the reinforced edge of the cloth down there to keep it all together.
Man, I’m glad this step is done. I’m going to give the bottom a second coat of epoxy an then probably paint.
Also, I’m basically out of epoxy (I have been making over-sized fillets for everything). I was afraid I would run out while doing the bottom glass but I went ahead anyway. My last jugs of resin and hardener are alarmingly light. I ordered another gallon of resin and half-gallon of hardener so I’ll have enough to finish the interior and the galley.