Mini chapter 0. Launching. Search for primary information. Plan
Using this boat as an example, I’ll tell you how repair/restoration or complete reconstruction works take place, as in our case. You can read about the history of the model in another article. About its original motor in this article.
I tell it in the form of a story, not bare facts.
We get to the boat covering 1,130 km along roads and about 70 along forest routes. We pick up the boat from the forest 1200 km (750 mi) from the workshop, tow it through the water, then load it onto a trailer and take it home.
We check the operation of the systems: the power plant, the steering system, and inspect the kingstons. We repair and prepare for launching.
Mini chapter 0. Launching
First of all, the boat must be on the water in standard operating mode in order to record all the performance characteristics of the boat in the logbook: speeds, acceleration time, fuel consumption, propeller dimensions and behavior on the water are recorded: what kind of rolls, how the rudder obeys, etc. Past entries from the logbook are also recorded and studied when and what happened to it. Repairs, accidents, etc. There is no such thing as too much data. Official sources of information are also studied to study manufacturing technology, materials used, and typical sores. After long-term use, it ends up in a workshop... for washing
First, the boat ends up in the car wash. Its difference from the usual one is the use of stronger chemicals to wash away old deposits and dirt. We write down everything we see, especially carefully studying old problems - impacts, repairs. We are looking for cracks, chips, traces and manifestations of osmosis.
The boat is built using fiberglass, fiberglass, and fiberglass mats. Fiberglass, fortunately, was not used. Therefore, the body is thin and durable, not overweight. Polyester resin was used, which is not good. If the tightness of the external gelcoat is broken (chips, cracks, etc.), abundant absorption of water occurs, which triggers a self-unloading reaction of the resin, thereby penetrating deeper and deeper. For this reason, all chips, cracks and their relative positions help us understand the picture of internal destruction that is hidden from view by the outer shell. And of course we take a lot of photographs, they will come in handy.
After the inspection, we draw up a road map (plan), which will be supplemented and slightly changed:
1. Hull work:
- Washing the body to make it pleasant to work with.
- Photo recording of damage, measurement of main dimensions, engine, shaft line, etc.
- 3D scanning, if necessary. But something went wrong with us.
- Removing all mechanics from the boat to the hull.
- Washing the Inner surface from traces of oil and dirt.
- Separation of shells. Top/bottom of body/
- Another wash of parts that were not previously available/
- 3D scanning of internal parts.
- Removing the power set, amplifiers (oak boards, mortgages, etc.)
- Washing previously inaccessible parts.
- Cleaning up damage from the outside and inside/
- Removing the gelcoat from the bottom of the body.
- Removing layers of fiberglass.
- Work with deep osmosis.
- Applying roughness to the body to secure new layers.
- Turning the bottom shell upside down.
- Rolling new layers from the outside.
- Heavy anti-osmotic primer.
- Flat keel. Production on a boat.
- Alignment of cheekbones, main lines. Checking and working with the boat's left/right symmetry.
- Turning the lower shell into the “normal position.”
- New layers from the inside.
- Manufacturing and gluing of new amplifiers and inserts.
- Heavy anti-osmotic primer.
- Gluing the power set.
- Installing approvals and gluing them to the kit and body.
- Heavy soils inside.
- Upside down.
- Punching a new shaft line. Drilling
- Heavy anti-osmotic primer.
- Lightweight epoxy primer.
- Painting the underwater part with polyurethane. Why not gelcoat.
- Flip the bottom half to the “normal position.”
- Installation of fur. components. See works on mechanics and power plant.
2. Mechanical works:
- Selection of engine for remotorization.
- Calculation of shaft line, selection of components.
- Foundation design for an engine, reverse gearbox, angular gear.
- Design of hull reinforcement. Embedded elements, amplifiers, etc.
- Design of cooling systems, auxiliary systems.
- Design and manufacture of brackets for attachments, engine mounts, etc.
- Design and selection of steering control.
- Calculation and production of deadwood.
- Calculation and production of the shaft bracket.
- Design and manufacture of Goodrich.
- Design and manufacture of stern tube sealless seal.
- Calculation and manufacturing of the steering device.
- Manufacture of high-strength titanium fasteners.
3. Work on the power plant:
- New engine. Sizing up everything.
- Unlinking unnecessary blocks, sensors, MDS, and launch permissions. ECU reprogramming
- Engine start 00.
- Installation and modernization of systems for working on a boat.
- Manufacture of brackets, pulleys, etc. for life support systems.
- Calculation and manufacture of the flywheel.
- Docking with damper and reverse gear.
- Connection of a reverse gearbox with an angular gear.
- Custom CV Joint on CV Joint. Design and manufacturing
- Design and manufacture of cooled exhaust manifolds.
4. Design of general electrical and power plant electrical:
- Will appear a little later.
Retreat
This list shows the sequence and algorithm by which the work needs to be carried out. Some of the work can proceed in parallel. In most cases, such work is not performed during repairs due to the scale and, as a consequence, cost. Only in exceptional cases, when the boat is of some value, can something similar be carried out on boats due to cost and labor costs.
The cost of such large-scale work is higher than construction from scratch, this is due to the limiting framework during the initial construction of the vessel and the difficulty of finding a solution - how to fit new solutions into this framework and not go beyond the boundaries.
The hull of a boat is not created by itself. This is a combination of the power plant, hull contours, payload and the functions of the boat that it performs. When one of the components changes, the balance of the entire system changes. For example, if you installed a heavier engine and the state of equilibrium of the entire system would go away, the planing angles, the area of the wetted surface, the angles of entry of the shaft line into the water would change and the efficiency of the entire system would change greatly. Or, even worse, when the type of drive changes, instead of an inboard engine, an outboard motor appears - the center of mass will shift much back, the point of application of force will be in a different place than the boat designers intended, and in the end it will be a waste of money. The same thing happens with the engine when they change the engine to a “saddle” one. with a large torque - calculation of fuel consumption and the boat cannot accelerate quickly. There are plenty of examples around the globe. Therefore, everything must be calculated and objectively assessed whether such work is worth implementing, or is it a utopia.
Mini chapter I. Washing the body
Washing should always take place if there is any suspicion of dirt, traces of grease, etc. When dirt remains, or even more so traces of lubricant, not a single resin, not a single glue will be able to fulfill its function! Even under the dirt, you may not notice important details: chips, cracks through which water penetrated and destroyed the body from the inside. You can do the work, but because of such details it will be useless: there will be no adhesion of the new layers of laminate to the old ones, the soil will not lie down, the embeds and amplifiers will not stick.