The photo above illustrates what happens when you build things in the dark and do not follow the instructions to the letter. This is a 1/4" gap running from the plywood scarf (I did a pretty poor job on the scarf) to the stern. The pencil line outlines the area that is the dip of 1/4" it tapers down to normal pretty quickly outside of this area. This is caused by the combination of the scarf being roughly done, and by the very last 2-3 inches of the stern bottom seam not being completely pulled in. I think the dip got worse and the sides came in and I really did not see it until all had been wired up and taped and the boat flipped over outside a few weeks ago. That said, I now need a plan to fix it. I came up with three ideas.
1. ignore it and it will go away.
2. foam core and glass over
3. wood core and glass over (similar to balsa core, but using 1/4" okoume.
I went with option 3 and things are gradually improving, but it still takes a ton of filler (WEST with microballoons and a little thixotropic powder thrown in.)
Along the keel area I have laid out a thick paste of microballoon and then cut up squares of Okoume to fill the deepest voids, just going as far as the 1/8" dip.
another view.
Since then, I have started to fill with the microballoon paste, and will sand with the long board to get all fair prior to glassing. I am pretty sure that when all is said and done, no one will know it is there. Microballoons are a boatbuilders best friend.
I hope to get a better photo posted next weekend showing how this all blends in nicely. If it doesnt blend in, I will make good use of the wood eraser.
update 6-14-14 (Flag Day)
Much better now. The stern is starting to get flat, and dip is disappearing. It takes lots of filler. But, It looks as if the plywood is at the right height, just slightly above the dip and is easy to fair with the long board.
I will bring the filler out to the edges after hitting it with the long board to find the high and low spots.
6-19-14
At this point, I am wishing I had applied foam core and shaped it. This is taking more filler than I imagined it would.
6-28-14
after a rough sanding with the long board, I went at this again with a thinner coat of filler. It will take at least one more sanding and filling to get it to its final shape. It is actually coming out well.
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