Deck being laid…

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Mar 162010

Yesterday the team started to lay the deck. This is a rather simple operation, except it is difficult (with a flat deck) to keep the 4mm thin plates straight after welding. But still, it is going quite fast. The skill of working with these thin plates was actually one of the reasons why I selected the Alunaut yard to build the Journeyman. Other yards would have made a heavier and slower yacht.


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Mar 042010

With a bit of violence it is possible for the welder to get inside. Good. We don’t need to get a robot…

Creative Clamping

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Feb 122010

Somewhere under all those clamps there is an engine mount. And it needs to be in the right position. Even after it has been welded, with all the thermal forces that the welding introduces. So Olari has created this artistic forest of bar-clamps to keep it in the right spot:

Major bloodshed? Or just leaktest…

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Jan 182010

Leak testing was started this morning. All welds are tested for leaks before they are grinded down to the final surface shape. Two different sprays are used. The inside of the hull is sprayed with a very fine white titanium oxide powder. The outside with a strong color agent. If there are even the smallest porous holes in the weld, the color will creep through the weld and show up as colored spots on the inside.

(…and in the background of this picture you can see the attachment points for the lifts are being put on, which means that we are now very close to turning the hull around)

Jan 132010

The keel is made from the SSAB super-duper Hardox 450 steel (remember the funny commercial about it?). Now this steel is not stainless, so it needs to be well protected from salt water. Usually you do this by painting it in epoxy. For the Journeyman keel this is probably not so good, since the steel will be flexing a little bit back and fourth when sailing. There is 4.5 tons of lead at the end of a 3.5 meter fin, after all… Ordinary epoxy will sooner or later crack in these conditions, which will lead to rust.

Now I found this nice Canadian propeller shaft manufacturer who has developed a protection paint for underwater steel. However, after learning that I would use it for something different than a propeller shaft they refused to sell it to me. This got me slightly annoyed, so thought I would play them a little trick. I contacted them through a completely different channel with a made up story about a propeller project, and was able to buy some paint that way. (Props to Alexander for helping out in this “scam” by the way :-)

Anyway, there are some points of the keel where it will be in contact with the supporting structure. In these points the paint will become scratched off over time, so we are putting small pieces of stainless steel in these spots. This means that as the paint is scratched off the exposed steel will be stainless and not rust.

In this picture your see the top of the keel with the mounting hole for the hydraulic cylinder that does the lifting (The keel can be pulled up from 3.8m draft to 1.8m for shallow harbors). The 4 stainless pieces that are being welded are the places where the keel will rest against the deck reinforcements when it is pulled up.