Fiberglass reinforcing the bottom

With great help from Jenny and Jennifer L we made a lot of progress today!

It was super hot today which both made things uncomfortable as well as challenging with the epoxy.

We started off sanding down the corners and surfaces we planned to glue. While preparing the fiberglass strips.

The challenges started early when the resin didn't look right when I pumped it and it came out much whiter than it should with particles from 1/4" downward. And the pump didn't refil correctly. After some investigation it appears that the resin has sat too long in the pump and has partially reacted somehow.

White precipitate in the resin pump. Unfortunately the focus in this picture is on the wrong part.

I pumped it a bunch and tried to clear as much as possible and we got back to relatively clear fluid flow. But new pumps are in order. And we're almost through with this batch of epoxy so that's not too bad.

As I noted in the last post there was quite a bit of gap in the front edge. So we started by trying out the silica thickener that I got to fill the gap. Since this was less critical I used the large pool of leftovers and tried to mix the hardener in in the right ratio and put the thickened epoxy into the gap.

Using the thickener in the epoxy

It seemed to work quite well.

After inserting that, we applied the glass down the outside, and then clamped the surface down. Hopefully with the epoxy squeezing everywhere it will come back apart ... ;-)

The clamped front end.

We moved onto doing the lower part of the lift duct. And ended up clamping it too for a small section of lifted plywood.

Duct post epoxy/fiber pre clamp

Duct clamp top size

Duct clamp bottom side

The clamps being attachable/detachable was quite convenient for sneaking the rod through the fan housing.

We continued from the front edge to the starboard side, and the rear. However we stopped doing the port side since it's fighting gravity and figured we'd wait until this hardened and do that side separately.

The end result was 3 sides done. And with a little extra time we also did the center joint between the plywood.

Edges done from the rear

Edges done from the front

And I had a little extra epoxy so I used the thickener again and filled in under the skid boards that I'd identified as having broken away previously.

Starboard skid board aft end

Port skid board aft end

Here's a timelapse. Unfortunately it's pretty long, but missing a good portion of the epoxy application due to poor batter management/tending.... Once the epoxy is flowing there's not much extra time for anything like thinking about the camera.