So, back again… as the keel is ready for a couple of years, now it is the time to make the bulb

Before molding the bulb, a negative form pattern has to be made. The pattern could be created from reinforced concrete, however before starting mix the indigents, a positive form is also necessary for the negative

Based on the original tracing drawings by the designer, I have created the 2D CAD model of the bulb and sent it to Peter – who has the CAM milling table machine – to make the 3D CAM model. The positive shape is formed from hard extruded polystyrene foam by milling.

The foundry instructed me how to make a negative form before the lead is molded. Concrete. Not enough to make it just smooth but it has to be dried as well to avoid the cracking during the lead molding.

The outer layer of keelbox is changed from plywood to solid mahogany timber with 22 mm thickness. The place of keel foil S/S bolts supports is already reinforced with the same way both sides.

		Keelbox solid timber reinforcement DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

After finishing keel foil shape – with placing two POM (Poly-Oxy-Methylene) tubes into the top of them – I could install the keel box into its final position: between bulkhead “D” and “E”. The two tubes made for supporting the d=12 mm S/S rod that has been pushed into the ‘horns’ of keel foil across the keel box when keel is lifted to down.

		keel foil adn box DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

There are two S/S316 tubes on the bottom of keel foil also to drive the S/S bolts supporting beaver tail torpedo bulb sides.

I drilled the necessary holes into one side of keel box according to the place of the hole on the keel foil, and after installation I drilled the other side holes using the opposite side as a ruler.

Gas

To install the gas bottle to the appropriate position (there is a regulation by the authorities that the gas bottle can’t be placed into the same airspace as the berth place, so it has to be separeted) – I had to make a special box that can be accessed only from outside (cockpit). Therefore I drove the gas pipeline from the cooker place to the aft where the gas box will be set. For this reason I glued small Mahogany plates into the bottom of hull inside. Clip pipe mounts to be drilled into the plates, not to the hull.

		Gas box DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

The oblique door frame between the bulkhead “E” and “F” (or from the keel box to “F”) was built in also. The front and rear side of the whole keel box construction has got Mahogany veneer layers – just for the spectacle.

The cockpit/deck stringers are also ready to glue into the slots of bulkheads (pre made in summer of 2010).

Some more pictures:

		Inside before deck top DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

Veneer to plywood:

		Veneer pressure DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

Rudder stock&plate

Rudder #1/.. DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

I could start the setting of keel box after finishing keel foil to the appropriate measures and forms. Keel foil consists solid Mahogany hard wood core (see: hard wood core) covered with unidirectional clothed carbon sheet and many layers of epoxy resin, and finally a glass cloth embedded in epoxy  (see: finishing keel foil 1. and finsihing keel foil 2.)

		keel box setting DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

After 3 weeks of epoxying and sanding I decided that before starting of setting the keelbox I add one more layer of glass cloth to both sided of keel foil. Just for sure. I have some glass clothes (used for coating outside the hull), so I did it.

		Finishing keel foil #2/2 DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

Teflon glide box is milled also so the another teflon block to reinforce the keel foil head on the top back side of it.

See: http://blog.visualsystem.hu/index.php/2013/06/16/finishing-keel-foil-12/

Last summer I started to make the keel foil (see: shaping the keel), it was time to finish it. Without a totally ready-made keel core foil – I can’t set the keel box exactly. Dudley Dix (the designer of Didi26) wrote down that the keel foil must be covered with glass cloth (unidirectional vertically). Unfortunately in my country, the UD glass cloth can be bought just in 32 kgs of roll. Because I need only some hundreds of grams, this was not an opportunity. But, a specialist (a chemist who is working for epoxy distributor, see: Alvin Plast) had suggested that I might replace UD glass to UD carbon /keeping the prescription of the original plan regarding to the resistance of high forces against the glass reinforced keel, the carbon cloth has 20% more strength in vertical/–> this way I could buy the quantity I need, not thousands times more.

The pictures and some explanation for them:

		Keel foil finishing #1/2 DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE

2 be continued…

After short pause I started the work again. The next pictures were made last July. This year I would like to finish the inside works and the the top of the deck and the cabin.

		Shaping the keel DIAVETÍTÉS MEGTEKINTÉSE AZ ÖSSZES LETÖLTÉSE