We have a mold

The plug was rubbed down and polished in preparation for the construction of the mold. The black top coat was applied on top of a pink sort of undercoat. This would help indicate where the rubbing down was getting too much as the pink would start to show through.

Front deck


I must admit that pink on black does look pretty cool, but no, it will not feature on a finished boat.

The shallow trough feature at the front of the cockpit does give an otherwise featureless front deck a little bit of character. Any water travelling along the deck should be channelled around the cockpit edge. If there is any risk of rough water, it is expected that a full spray deck will be fitted.

Front deck drain trough


The rear deck mirrors the front in that it is flat and feature less.

Rear deck


However the shallow trough at the front has be replicated at the rear. This does not really have any practical application, but it looks nice.

The plug is pretty much redundant once the mold has been constructed and is usually thrown away, but it has cost me £1,800 to get to this stage so it is safely stored away. It is also my insurance if I need to make a new mold.

Another £1,000 gets you a mold. The last stage before an actual boat can be made. The plug remained in the mold for a week to ensure an accurate facsimile and no movement when the fibre glass was still “green”.

The mold


All the time taken to achieve a smooth finish has paid dividends on the mold. This will deliver a smooth finish on the boat, and ensure that the mold does not stick to the gelcoat.

The cockpit


We’ve created wide flanges to help form an accurate and consistent join.

Mold flanges


All the hard edges have been eradicated on this boat to help the carbon form in the curves, thus reducing the risk of trapped air pockets.

In a few weeks’ time the first boat will pop out of the mold, and the maiden voyage will be the moment of truth when I’ll know if it meets my expectations. This time the design is based more on gut feel rather than my trusty Naval Architect with his CAD, 3D modelling and fluid dynamics algorithms. I’m quietly confident that it will deliver an increase of speed compared with the Duet, albeit with some trade-off in stability and payload capacity.

I also have some ideas for construction. I’m planning a layer of carbon fibre on the outside, supplemented with a layer of carbon-kevlar on the inside. This has proved not to be rigid enough on the Duet, but I’m going to use additional ribs at regular intervals from stern to bow which in conjunction with the full cockpit length flange, should form a rigid framework.

I’m looking forward to an interesting summer putting the boat through its paces.

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