#14: From the Top

We’ve finally begun BUILDING the boat! Yessiree, no more just staring at the pretty drawings. It’s time to put these plans into action!

Well, let’s take it from the top, literally: We began with the roof on April 1 by using the plans and the kids’ wicked Lego skills to assemble the forms out of MDF (medium density fiberboard). The MDF would temporarily hold our roof panels in just the right place.

Our plan is to first glue together the cabin top, and then lift it up to the ceiling of our barndo to get it out of the way while we finish everything else that will rest below. Sounds great in theory, but theories are made to be tested.

Heavy rubber horse stall mats, the containers of liquified hardening agents, and strategically placed screws were used to hold down the roof into its desired shape.

Nick used a router to create a channel in both sides of two flat pieces, and with that, a biscuit joint was glued in place to hold the two panels together.

Nick got to try out his fancy new mask for sanding.

My job, for the most part, was using the scale to measure out a ratio of resin and hardener (fast- or slow-curing), plus possibly some cotton flock fiber (for structural integrity), microspheres (for ease of sanding), and/or fumed silica (for thickening and strength). Anyone want some melted “marshmallow” on a stick?

We pre-wetted out some fiberglass strips by brushing resin over them on butcher paper, and then we painted more resin on top of the strips when they were in place.

Tristan helped place the edge of the roof, which will act as a grip while walking along the boat and also as rainwater collection.

And here’s what it looks like now:

Next up, we’re waiting on two electric hoists to come in the mail so we can raise it, flip it, and glue the underside!