On this week's episode of Onboard Lifestyle we crack open our rudder cassettes on our custom 435 catamaran SV basik. This was a project that was keeping Teal...

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hey guys welcome back to sv basic

finally the Sun has come out it's been

raining for two days straight so my dad

took this opportunity to take the rudder

off the salon table now we don't have to

eat around to this work let's go see

what he's up to okay last week we worked

on the rudders here's our port rudder

this one's dang near done got multiple

laminations lapped up over the edges

blended in nicely I do need to put one

more lamination on this top edge to make

me feel a little more comfortable

here's next Robert Redford I've got the

lamination Tom but I haven't sanded this

one out yet so you could see this

lamination how far I've lapped it over

all the edges all the way around so I

need to work this one over a little bit

not too much work and I will do that top

lamination on this one as well but the

real work today is on the rudder

cassettes a lot of people don't know

what rudder cassettes are and I'll

explain what they are but these attached

to the top of the rudders and it gives

the ability for our rudders to kick up

and out of the water if they were hit or

just to pull them out of the water if

you want to anchor in shallow waters

where those go let's walk over here

here's our sugar scoop

here's our rudder trunks and that's

where those cassettes slide in they

slide right in here

there was a hinge point so the whole

cassette could hinge up and down and

pull the rudder out of the water but

since we're eliminating that we need to

put these cassettes in permanently so

it's gonna be a lot of work that goes

into these cassettes I want to beat them

up make sure that they're clean dry

stable and strong so I'm gonna work on

those today get those in tip-top shape

and then we'll be mounting those in

permanently

I can't mount them permanently yet

they'll be temporarily tacked in until

we get over the haul-out facility then

I'm gonna blend those into the deck and

the hull so you won't even see them

anymore so let's get started on those

okay let's see if this explains it a

little better here's the profile of our

boat right there and here was the kick

up rudder mounted right there originally

the boat had an outboard that could be

deployed it would kick down in the water

and if you want to anchored shallow

water you raise it up and kick up the

rudder and the rudder would kick up in

this position right here that way could

anchor nice shallow water but now we

have a fixed sail drive right here so

there's no need to have this function

because this is the low point so I can

eliminate all that crazy hardware that's

associated with this kick up rudder

eliminate it and glass this cassette

directly into the boat and have a

permanent rudder now keep in mind we

also have a deployable dagger board that

comes down and I could set this at any

level actually it's right about there so

this will use as a curb feeler when

we're anchoring in shallow waters to

protect the sail

and the rudder will probably deploy it a

little bit further this is much more

sacrificial than these two items at this

point so that's our plan Q before I will

start working on these cassettes I'm

just going to give the starboard rudder

a quick sanding there's a lot of sharp

little burrs on this thing that way I

could set it aside

I feel good about these now let's get on

over to those cassettes check those out

been laying awake at night thinking

about what's inside of those I think I'm

gonna have to break one open to see what

I'm in for

so we have a couple extra days of

sunshine which is great so this morning

teal has pulled the runners out of the

boat and he has done one more layer

after standing down with epoxy so it's

just drying now who's kind of sticky and

then at once that's cured we can stand

that down again and start doing the

fairing compound on that just to get all

the imperfections out so while that is

curing he is back in to the sugar scoop

standing and working on anything else

that needs to be done prior to putting

in the linkage and I'm going to be

working on the cassettes so the

cassettes are the top portion of the

rudder that I'm standing out and it

actually is really light so I think that

it's hollow or foam cord on the inside

tail is going to actually excavate part

of it out to see what's going on on the

inside because it looks like there's a

high spot in the middle and that's

really bothered him so I'm getting to

work

okay so my part is done

these are looking a little rough so I'm

gonna let Teela sessom and let us know

what is the next step to get them back

in order in the meantime I gotta get

cleaned up because I gotta get Dinner

started okay Linda did an awesome job

sanding these down and I could really

see what's going on now all these

different layers these sides actually

don't look too bad I mean I could see

through here it looks like the interior

looks great

nothing's wrong nothing's bad but the

other sides of both of these there is an

issue when I was taking these out of the

rudder trunks they both stuck a bit

they're supposed to tilt up and down

nice and smooth but they were wedged in

there and now that they're standing down

I could see why let's take a look at

this okay so look at this face I could

put a straight edge on here

any other uneven but they're fairly flat

not much gap on there but I turn these

over and look at this side there's a big

bulging area on it it Bowles's up looks

like 5/16 of an inch maybe 3/8 of an

inch

same thing look at that this one's

probably even more this is easy 3/8 of

an inch so it's these two big humps here

that we're binding these in their trunks

I don't have to cut these out and figure

out what's going on in here I have no

idea I'm guessing maybe spray foam was

added in there and it ballooned these

out slightly I don't know let's tear

into these and find out

okay these look like they're ready Lin

did a good job prep needs up for me I

can actually see the structure inside

now I mean it can't be much to this

probably wave five six pounds are very

light I could see a little wood through

here down here and along here this piece

must have been filled in and this is the

side that's pretty flat you know it's

ugly but this is all totally fixable I

can make that look good it's this side

here look at this when you put this in

the Sun let me flip this over we tilt

this away from the Sun look at that

Ridge let's get this out of here

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ok I got a better idea now what's inside

of these

looks like this is a high density foam

that they put in it for some reason this

piece cupped up and that's what I was

seeing on this home

but this wood looks like they have to

marine-grade plywood

even if someone just cut it over here so

what I need to do is just clean this up

fill this in with something a little

more stable probably use ninety core and

then laminate over the surface and these

cassettes should be good to go

okay I feel good now that I've looked

inside of these let's put them back

together okay the next step is to fill

this in and I have my knife Canaccord

here ninety core and I've played around

with some of the different thicknesses

trying to see what will work and it

looks like a piece of 3/4 and a piece of

half-inch will exactly fill this in so I

just have to take my old pieces I just

took out and figure out

this little puzzle well I wasn't too

hard there you go where does this go

right there I'll tape this together and

use this for my template

with my template on here

I'm just racing it out

just takes a nice sharp razor

just make sure you keep your blade nice

and straight I like to score the surface

first right on my mark and then plunge

through on the next pass

okay I've cut a few 90 core pads in here

to bring it up to the right elevation

let's see how this stance it looks

pretty close I'm happy with that

so we'll get this all epoxy it in and

let this cure overnight I think I'm all

set up here I've got my West system this

is 105 with a 205 hardener I've got my

roller a couple of gloves a spreader and

my piece of honeycomb I'm just not real

worried about the strength of this the

strength lies in the perimeter of this

this is just a gap filler and a way to

fill it and keep it light

they don't insert all around the

perimeter thick and epoxy that'll hold

it in the right plane let this cure up

overnight and then I can start layering

glass cloth over this that's where the

strength comes so let's get going to

this

okay now I'm gonna saturate

my nine core pads these actually have

carbon-fiber inlay in there you can see

that in there

Lyn's mixing me up some thickened epoxy

for the next step

nobody call for thinking epoxy I did

you're gonna have to start calling me

your epoxy queen now what you want

cuz I'll do it she's pretty good at this

look at this perfect like think peanut

butter

all I'm creating is that just a light

weight filler

everything I'm adding here is this

ounces but it'll give me a nice

substrate to lay up cloth on to I just

insert it in I want to saturate this

face now I'll get some clamps on this in

a minute okay I'm gonna take my

thickened epoxy here squeeze it go

around the edge here if I was going for

more structural I would have filled all

the honeycomb around this but since this

is just filler

this would be plenty to hold in place if

I get my cloth

okay I've taken a little piece of wood

here and wrapped it in plastic wrap this

is gonna bend this panel in and hold it

in a nice plane with everything else

I put this just the plastic wrap on

there to keep this wood from sticking to

the surface that looks pretty good

I'll be able to plan this right out

okay getting my mess cleaned up out here

got plenty of epoxies on right now let's

take a look at these cut these bacon in

the Sun right now look these cure

overnight we'll take a look at them in

the morning

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hey good morning guys it's another busy

day morning Emma's just starting school

and teal already went out to grab some

tools to get his day started as well so

let's see what he has going on today

there you are

good morning okay let's do this so I

gotta break these down see what I'm in

for

everything looks like they planed out

nice kicked overnight so let's take a

look at this I'll put plastic wrap over

my supports and watch this come right

off they don't stick it off okay

that's looking good it nice and flat

much better than before

let's get these sanded up and what I'll

do is start fairing in some of these

defects on this when I lay the glass I

want it to have a nice smooth surface

okay next thing I'm gonna do is go

through here now that it's all sanded

out and find any imperfections all this

dimpling in this maybe a couple of this

pitting here there's a low spot over

here and I'm gonna ferrule this out I'm

going to use a wet system epoxy with a

4:06

silica filler this is hard to sand but

it's very durable very tough and since

this is at or near the waterline I want

to use something that's strong so the

trick is get this on as smooth as you

can because sanding is difficult

somebody's in a puppy timeout

don't attack your neighbors it's not

nice he looks so sweet

with just a minute ago he was barking

like crazy at her neighbor let's see

what's going on here

tl has turned our head into a temporary

epoxy booth to get these to cure fasters

because it's really chilly outside

well-ventilated and closed off so we

don't get any fields or anything not

that we'd get much and I am making lunch

teal has been out there since about 7

a.m. and he has not taken a break so I'm

gonna see if I can entice him with the

sandwich

and see if he will take some time to

take a break

so he didn't notice me I'm gonna try to

stick this under his nose and see if

he'll take notice you want to open the

door

okay we'll just bring you in good

okay we're getting off the boat for a

minute

heading over to mo hi that is a museum

within walking distance emma has a

school project needs doula research so

this would be perfect for trying to

catch up with the girls they got a jump

on it already you guys ready to go

here at multi the Museum of History and

industry let's go check it out

gonna take a selfie

mahai was the perfect place for me to do

research for my social studies class

it was amazing walking through the

museum gathering so much information for

my project I'm so excited to work on my

project

and I know I will be totally proud

get a lot of information for my project

so let's get back to the boat

speak up projects going on in this sugar

scoop teal is working on the runners

well he was working on the runners but

obviously now he's on the cassettes but

you can see that we are taking full

advantage of this nice weather and

getting as many projects done as

possible before we set sail we're gonna

end this video now but I wanted to take

this opportunity to say thank you so

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you next week

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