Gluing on the doghouse roof & How will we finish the bow? [EP98]

#boatbuild #sailing #boatrestoration #boatbuilding
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[@soanonso]

I think your idea for shaping the bow using the stacked foam makes sense, and already looked better than with the old fiberglass piece.

[@brba]

A clipper bow (however small) is not suitable on an Open 60, I think. A straight bow line and sharp angles to the bow sprit makes much more sense. But it is not really that big of a deal.

[@TheMikesylv]

Agreed

[@ryanrozell942]

I agree!

[@gmoose777]

agreed, not really open 60 material but with all the other mods a fitting design quirk to clean the lines of the gussets

[@garys4300]

I like the direction you’re going with kind of adding a sweep there, I think it will look good!!😊

[@ronkluwe4875]

Matt - my vote would be to remove the rest of the false bow down to the water line and have Evan design you an entire new false bow. This was you could incorporate the shape you are looking for without making it look "add on". Another thing is that, if you wanted, a new false bow could also incorporate a bulb bow if it was felt that more buoyancy is needed due to the gennaker now being forward of the bow. Keep pushing on, the boat is really starting to come together.

[@chicobicalho5621]

@ronkluwe4875 this is by far the smartest solution, and the most logical as well. This way all the old foam in the current bow is removed, and everything is spanking new, in adition to the shape being one integraded element, designed to fit within the sprit and its gussets. Incidentally, that bow smashed against the side of a large ship, so, who knows what hidden damage is in its lower part as well? Also, perhaps the new bow could be made from carbon, so small bumps, can be more easily absorbed, but this is up to the experts.

[@ronkluwe4875]

Chico - good points. I would use Kevlar instead of carbon fiber for impact resistance as carbon fiber is stronger weight for weight than Kevlar, but Kevlar has significantly more impact resistance (e.g., why Kevlar and not carbon fiber is used in bullet resistant vests). That, along with the crash bulkhead, gives added protection against a potential impact. With the number of cargo containers floating in the ocean today, having a strong bow is pretty much a must for a blue water sailboat.

[@chicobicalho5621]

@ronkluwe4875 Yes on kevlar, what I had meant to say is that a more resistant composite than fiberglass may not be a bad option, in case they touch a coral in French Polinesia, or some other small mishap (Goddess forgive), more like a bit of piece of mind. Ever since I learned about Dick Beaumont and Kraken Yachts, my perspective on bluewater sailing and boat safety has changed completely. Regardless, redoing this bow with exactly the shape Matt and Janni want and building it in kevlar with new foam seems absolutely logic, and the way to go for them.

[@chicobicalho5621]

13:50 Janni definitely needs a pay raise! Lowering the roof, while shooting impeccably, was really impressive.

[@jaygee5693]

I thought the same. Professional-level camera work with precision rope-work!

[@26N80W]

You could also draw a line from the start of the flanges on the sprit down to the bottom of the bow. Create a new bow which would hide the flanges.

[@danpetro3155]

This. That way there are only two lines; the one from the bow and the sprite. Simplifys the whole look. Please don't curve the bow as you implied. It's race boat

[@point29]

I was thinking the same thing, remove the entire false bow and draw a new straight line from forward part of gusset to bottom of real bow. Though, the foam model looks better than re-using the old one.

[@claverton]

Exactly what I was thinking, except I couldn't describe it without drawing it ;)

[@boatbikemike8571]

This gets my vote as well

[@renexxx2017]

Agree, build a complete new bow from the waterline up

[@120Livi]

Wow! I remember watching the doghouse build..... 2 years ago! I can't believe it's been that long

[@imabeliever244]

Time flies when you're watching someone else work! lol Sure doesn't seem like it's been 2 years already though.

[@FranklinCrone]

Nice job on the roof. I think you should investigate cutting the bow back to the vertical lines you have marked and make an entire new bow end to the boat with a squarish entry into the water as in many newer boats. The good thing is you can decide the amount you want squared off and the depth of it ie.. to the waterline then vanishing etc. good luck with your decision.

[@alwaystinkering7710]

Suggestion for the bow. Use that void! You could install docking/anchoring lights, a horn, or a nozzle to wash off the anchor.

[@TheDuracellProject]

Very interesting idea. Thank you.

[@holgerlafrenz2895]

I agree with filling in between bow gussets. Otherwise they will become an area to catch waves smashing into the bow sprit. Great work on the boat.

[@dcallan812]

Great update nice to see the roof structure getting worked on. Nice Eric Satie music clip.

[@Psychobilly]

Matt!!! You’re on the right track!!! Glue them foam pieces in and shape her like you like it. That’s exactly what I was thinking.

[@chuxmix65]

Thank you for putting a bell on your cat! It's so simple. Growing up in the Seventies it would have been unthinkable... Domestic cats can still have fun and get exercise trying, but failing! Big step, "putting on the lid"! I'd imagine there's fitment, fillets, gussets and whatnot to come!

[@newzealandfromadjimini2cor452]

I so lived the tension when the roof was coming down .... well done you managed that awkward job so well. 👍

[@sailor5026]

Realize you have a responsibility not only to yourselves for safety at sea, but also to the legacy of Duracell herself. I do appreciate the way you walk away and let things percolate... Bud McIntosh used to have his “thinking chair” next to the pot belly stove. I vote for forming the new stem with shaped, layered foam pieces.

[@TheDuracellProject]

YES! I need a thinking chair in the boat somewhere….hmm.

[@Bladerunner264]

These watershed moments make amazing content exceptional. Can't wait to see Duracell moored up in Ireland after the transatlantic spin

[@dinacaldwell7522]

Excellent use of block, tackle and pulley. My grandfather built his first home alone like this. Simply inspiring

[@bardhaase8758]

Used blue tape the mock-up The Bow Before You shape it

[@chicobicalho5621]

Just dawned on me that the new shape for the bow may be ideally conceived in 3d modeling, especially since you already have the bowsprit modeled in 3d. This way you can do different studies and compare the different renderings side by side, providing ideas and solutions to incorporate the new bow shape to the gussets, as well as the best means of glassing all pieces together, taking away all the guesswork, so, you will feel much more confident when the actual building and glassing takes place.

[@damonzucchiatti1838]

Your idea to shape the bow to the gussets will look very nice.

[@garys4300]

I like the direction you’re going, Matt kind of adding a sweep for lack of a better term. I think it will look really good😊

[@CAPTJohn47]

Matt, you are a brilliant practical engineer.

[@chicobicalho5621]

Matt, @ronkluwe4875 came up with a really logical, and smart idea for replacing the whole bow, and designing a new one to fit the shape of the sprit and gussets exactly as you would like, without it being a splicing job, and at the same time replacing all the foam, so everything is brand new, like the stern, which turned out so beautiful. I hope you, Janni and that adorable feline have an excellent Sunday.

[@dick8193]

I'm no boat builder, but the foam design you're working on looks much better to me.

[@davidwilkinson333]

Seeing the doghouse on and primed will really start to show Duracell's new lines: so exciting after all this time and effort, so exciting! You must be starting to feel you're beginning the home straight now! Such kudos to you guys for forgetting this far and so professionally too 👍

[@SR-gd7vt]

good therapy to watch the progress!

[@ddouglas3687]

I think your idea of the curve to meet the sprit is the best but you could simply make cardboard mockups, including the color scheme, to really see how it'll look. You could go crazy and make a full figure head! Maybe the inspector! 🐱😂 Good stuff!

[@MicBruise]

A replica of Janni would make a great figurehead!

[@teeanahera8949]

Now there is a wonderful idea. A figurehead! 😅 Reminds me of a NSFW poem I heard when I was a young tacker.

[@user-yd6ef1yo9d]

@@MicBruise 😄

[@christoskallinikos5455]

Hello, I've been watching the build since episode one, but this is my first time commenting. I had an idea about the bow shape, and I thought to share it. What if you continue the vertical cut you did to the damaged bow almost all the way down, maybe up to where it crosses the red line. Then tilt it forward, essentially keeping the old shape of the bow but at a more aggressive angle. The tilt should be enough so the extended old bow end meets the upper corner of the gusset, where it connects with the bowsprit. Of course, there should be some fairing to be done to blend the gussets in, but from my napkin sketch, it seems doable and not so aggressive. Keep up the good work.

[@charliemcgrain]

The way you were filling out with the foam under the bow sprit looks like the way to go. You don't want a water trap under the sprit that will cause drag. Any water that rises as the bow lowers needs to get pushed out sideways. But massively impressed with the work, man. Great job and thanks for sharing the ride. She will slam, and her stern will be "slapping" at anchor, but lots of fun and fast passages.

[@hughwilkinson8541]

As an architect i would definitely go with the original bow option 1 because it respects the original boat's shape whilst clearly articulating your addition. Each will be beautiful in their own right. 2 trying to blend the two i assure you will be a visual disaster or as we say in Aus, a dog's breakfast. 3 personally i would cut the gussets off and make the original bow shape the main vertical gusset. Good luck Matt Cheers Hugh 2

[@dinacaldwell7522]

This looks simply beautiful in form. Great lines on that doghouse roof running with the walls. Just divine.

[@ThoughtfulWander]

More progress! Looks great! Keep rolling along Duracell team! 👍👍

[@brucecampbell9138]

I loved the music that you used while Matt attached the top of the dog house. ❤

[@philipschrantz8402]

FWIW, the foam core shaping makes sense. I’d suggest shaping the foam so that it smoothly integrates into the diagonal gussets for the sprit in a “carrier bow” transition so that water will shed evenly off both sides. Some complex curves for sure, and perhaps challenging to make symmetrical. Also consider how close the point of the anchor will be so that inadvertent swinging of the anchor durning weigh/drop operations…

[@gsh341]

That's something I've been concerned with as well. Maybe get a local metal shop to work a piece of stainless steel to match that area and attach it to protect the bow.

[@TheDuracellProject]

I also worry about the bow encroaching on the anchor. Thanks for the comment.

[@benthomas8411]

I like the idea of flaring the bow out to the gussets and fill in the gap for waves to flare out and not go into the anchor chain track and hull? Just like your foam inserts Love the videos, great progress with the roof, looks awesome Thank you Ben

[@svennekornesvag4071]

Shaping the bow is gonna look best imo , but i would start the curve/slope further down to get it more of a straigth 5-10° line from the bottom of the bow to the bowsprit

[@benjaminstone6496]

I think cutting away more of the bow further down to create a better line from the curve, might give a better blend between the two.

[@tylp4199]

Beautiful again! Love to watch your work!! Real craftsmanship..

[@ianmathiesen2416]

With the more modern sharp lines of the bow pulpit maybe more of a "straight" or vertical bow makes sense. Not fully vertical. Just a thought.

[@moronews2582]

I definitely like the shaping the radius in to the flat at the bottom of the sprit.👍

[@bobperry1269]

Great Job on the roof. Like the curved bowsprit piece as long as you can get it watertight.

[@tomjacobsen664]

Extend the original profile out from base to deck to incorporate the new cons. It's basically esthetic and if need be sacrificial anyway

[@karlnielsen8111]

Great job guys, I would certainly buy a boat that you have either built or refurbished. The bow stacked with foam and faired will be sweet

[@davidantill6949]

I'm really impressed by the two of you. Well done

[@bobflores]

The stacked foam to shape the bow seems like a good option. I do like having the bow shape incorporating the bowsprits gussets. It adds a little more shape and blends the bowsprits in to the bow more seamlessly. Not so add-on. Big day gluing down the cabin top. A big step forward. The inspector was really checking out that ladder. I hope it passed muster.

[@dennisg8164]

Hola Matt. I watched a guy building a custom fender for a custom truck. He used spray gap filler. He filled out the entire area with the foam and then took a body file and started shaping. He liked doing it that way because he could just reapply foam if he didn't like the result and try something else. It was quite slick, easy and inexpensive

[@HansWeberHimself]

Like the foam shaping idea. Form follows function. The gussets should be integrated.

[@chrisbartlett6022]

Huge step ahead. really looking forward to seeing how the bow works out.

[@lvdriver4]

I would use the old piece like you have it cut & fill it in with spray foam or another foam and then Mold it to the new shape of the bow

[@skyd8726]

Matt, I'd have a curve on the underside of the bowsprit and blend that downwards to the original bow. Just a nice smooth transition. As an aside, my Father told a tale about some boatbuilders who had a very unpleasant customer. In return, they routered a groove all the way across the top of the transverse beams, then inserted a ball bearing into the groove. Then they glued on the top of the doghouse. Every time the boat tacked, the ball bearing rolled across & banged into the leeward side! I guess he had already paid the bill before going sailing in his yacht...

[@VikingDane]

I like the look of matching the gussets, you could also add a pocket angled towards the water for an anchor light 🤔 no headlamp in the dark and easy clean up would be cool.

[@stevenweiss9124]

I think creating a bit of reverse curve at the stem is worth trying. It will blend the bow sprit into the hull - definitely make a distinctive profile!

[@seananthonyjohnson]

Only because u asked how I would do it, ' cut more of bow out n make another arch more along a better looking line. I'm glad u tried the cut foam before closing.' thx for ur vids, I really enjoy being involved but I only truly want to watch n learn. thx again 👍👍

[@c.a.mcneil7599]

Use the old cone and get you some of that rattle can chrome. Spay up that bowsprit and keep what you have left of rattle can. In case your bowsprit starts to rust the you can protect it.

[@johnmeier270]

Can't wait too see the finished sail boat

[@bikerXtrash]

My $0.02. Use the old bow section as you trimmed it. But then fit a flat piece of foam, just one piece, to the underside of the gussets and blend it into the old bow section. then fiberglass it all together (?)---I don't know a thing about glassing.

[@claudehopper9813]

Great work , you're doing the grand ole boat justice ! She'll be good for another round the world race !

[@flossey100]

That was stressful lining everything up this week and the internal space has a different sound quality now….Nice job…..keep thinking about the bow shape……maybe the shaping needs to start further down into existing section for a nice sweeping line. 💖💖💖🇦🇺👋

[@junepeck4259]

I would mold the bow in an arc so the bowsprit and bow blend together better. It would add additional support and strength, plus it's aesthetically pleasing the look at.

[@Nena84734]

It sure did go well, nice plan Matt, nice filming, as always, Janni! Great call on the bowsprit, it’s always best to move on when you’re not in love with the choices. Duracell doesn’t have a lot of swoop lines, if I remember correctly, although, the shaped foam wasn’t bad.

[@TotalBoat]

Great job on the roof! 💪💪

[@TheErmerm999]

an old car building technique for getting the lines authetics is to white wash the area and then use a big chunk of clay. and sculpt it up

[@denisleclerc4798]

Super cat 😹 je suis très impressionner par tes façons de faire.

[@robertpitts6041]

Hard foam. Shape in place to your liking then use that to build your shell and glass in place.

[@samknight9577]

I don't envy you when fairing the bow. Definitely one to sleep on.

[@russellesimonetta9071]

Definitely blend it in. You are on the right track

[@roobarb8463]

Matt, Thanks for the updates each week... With regard to the bow design, can you alter the angle of the bow from the waterline so that when the boat is seen in profile the bow runs in a straight line from the waterline up to the join on the underside of the bowsprit just aft of the anchor roller? At the moment the gussets look a bit 'jowly' if you follow the original profile of the bow, and re-angling from halfway up the bow to incorporate the gussets may begin to look a bit like a clipper bow, which is not really in keeping with the rest of the boat's design. If you started at the waterline with a relatively sharp bow it could broaden and perhaps turn into more of a curve as it went up so as to incorporate the gussets.

[@chrismonroe8582]

I love this show/project. The temptation for me on the bow solution would be to replace the whole false front maintaining the starting curve at the bottom and straight line to the bottom of the new construction. Further ambition may be to make it proud enough to accept the point of your anchor with an integrated changeable port for that

[@anthonyrondolino8148]

I would suggest you paint the bow and bowsprit with some primer to get a uniform color so you can properly judge the appearance of the completed unit.

[@UnPetitPique]

Great work it's a big moment, almost waterproof haha :)

[@amazonhippie7826]

I’ve been wondering/concerned about how you’re going to blend the bowsprit to the bow. I’m definitely not an advocate for just using the old bow shape. When you stacked the progressively protruding foam pieces under the bowsprit, I could picture the final outcome. And that is 100% what needs to happen. It will give it a well-thought-out, molded-looking, properly-flowing profile. It’s what needs to be done. And you seem like you know this already.

[@warrencranch2614]

I'd shape the foam from the curved section to a square one at the bow sprit. Get happy with the contours then make a mould

[@markchodroff250]

I think you should make the bow cover up the supports and have it a more fluid flow to the bottom of the bow sprint , like a small clipper bow !

[@krispress7824]

Think the foam bow now that I see what you are trying to shape it like is good idea.

[@rileyhowser2709]

Looking great guys!!! And I absolutely loved the background music for this vid you should use this style of music for every video!

[@billiam4054]

the foam looks better than the insert of the old piece, but for a better finish I suggest that you start from the bottom giving a clean line all the way to the sprit

[@ducbox572]

With the boat 3D modeled in Rhino, you have the opportunity to play with an infinite number of bow shapes.

[@kevniel7398]

So, I joined just cause I wanted to compliment you on your attention to detail. I’m sure that roof is glued on just fine but rather than filling the voids with a little Bondo later, you elected to epoxy it up right then. I can appreciate the commitment to the craftsmenship. I learned a bit about fabricating my hard dodger also, on my Hardin 45’. I have five 250watt panels and 600 amp hours of lithium batteries, and two 3000 watt inverters. One is designated for large power draws (water heater, pressure washer,etc.), and is mostly off, so as not to draw too much power while on standby. The system is 12 volt, I tried 24 but had issues with getting the all in one charger-inverter to turn back on and charge, after the batteries went down. With more amp hours now they never go down but, just a bit of insight to share regarding that. Nice boat, see ya out there ! Sun Ketcher out…..

[@yachticus]

Hey Matt - I had a thought - mainly aesthetics - an awful lot of the late model yachts have a similar bowsprit - but the single biggest difference is their final layup is covered in dark carbon - and really highgloss clear. maybe making it distinctly separate from the rest of the yacht - will provide the aesthetics you are looking for.

[@CG-99]

I would redesign the bow shape from the waterline up and go with a very modern looking plumb bow, or even with a slight reverse sheer.

[@gsh341]

If it was me, I'd make a rough and oversize form and use 6 pound pour foam to ensure you completely fill the area. Next I'd sand it down to the final shape which would be a nice flowing curve. Then cover that with a bunch of fiberglass. I'd also look into some sort of metal or sacrificial protection for the front edge of the bow to protect against a swinging anchor.

[@MaShcode]

I’d consider keeping the original bow shape and curve the gusset since you’ll need room for any anchor play. Use glass and compound to fair the bow and gusset into a unified shape.

[@carlamerritt490]

Love your channel and content. Your a great team. And yes, Inspector included! ❤ Oh, and I'm sure your final bow design is gonna be amazing!

[@user-Adam72]

In the video the bow / bowsprit both look a bit angular and disjointed. Duracell has smooth lines with small radius corners, and matching that aesthetic will help make it look one piece. For the bow / bowsprit merge, I would actually take a different approach. Take a flexible rod / batten and attach it to the hull along the underside midline, and then bend it up to meet the bowsprit at the point you want. This then gives a nice organic curve all the way through the bow and will look like the bow was designed to meet the bowsprit. Once that line is set it should be easy to use horizontal battens along the sides of the hull and curved in to meet the vertical batten at various levels, thereby giving you smooth lines to work with. Some of this can also be done by using cling wrap film stretched across the surfaces (use several layers in different directions) to give a smoothed surface that looks solid. I have found that it's hard to visualise compund curved surfaces like this unless you have everything the same color or a visual 'barrier' to work with.

[@TheDuracellProject]

Yes making things the same color will help a lot. I plan to paint the sprit the same color as the boat, which will help hide the gussets a bit to whatever bow shape I decide on.

[@Deutschtown]

Nice shelf for a figure head.

[@brianwills5707]

You might use approach they use make custom subwoofer enclosures for cars. Stretch some stretchy fabric over gap and paint with resin. After hardening, you can remove it and use it as a mold or basis for the final shape.

[@Vendelcrow1948]

Hi gang from mikke,now on the greek island Karpathos..🇬🇷 Fine video,as usual Janni quality 👍❤️!! As for the bow,round up towards the bowsprit,and it will be a unit...👍 Allda bestest from( temporarily) michailis...:-D

[@phensriwood8081]

I like to use tie down ratchet straps for clamping long distances.

[@sucapizda]

Thanx for the Satie.

[@jodywade5617]

Awesome team work you two.

[@KD0CAC]

I would have thought you would round the corners of the roof - to not get poked ? Looking good ;)

[@TheDuracellProject]

we will!

[@MrTidjon]

hope all is fine! Missing you guys!!

[@offtherichter7]

Best sailing project ever Matt. Every design, ascetic or other modification you have made my eye has completely agreed with. And a great idea to set something aside before building something you don't love. I also think sanding down the foam to make the bowsprit look more like part of the original mold is going to look best. brilliant work, and thanks for sharing ;)

[@idontlikeit.7822]

Putting the roof on basically single handed was totally trick….Kudos maestro…….not meant to denigrate your # 1 helper

[@lajosfidy3785]

You could take inspiration from the newly launched Baltic 111 Raven's bowsprit. That looks like an addon but in a good (and brutal) way.

[@kronopolis7]

I use fleece to get nice curves for speaker enclosures. Maybe you can try out a piece and see how it lays in place. If you like it you can put resin on it to make a shape.

[@joecioe8566]

I am looking forward to seeing the beams and roof. i am sure that it is going to look really nice. My though on the bow is to remove more if not all of the original bow and form it so the gussets are lost into the bow. great job I am looking forward to seeing how you finish it up

[@jakobnordin]

No Idea HOW you could stay calm! I was stressed out just watching the roof getting married with the boat, there was alot that could have gone wrong. Wow!

[@rickpawl]

I definitely like following the shape of the gussets and blending it all into a nice graceful curve. It really does look better and as we all know, form follows function.

[@camyw790]

I think your idea of shaping and following the line of the chain plate brack will look great. It will blend the existing hull lines with the new chain plate.

[@bdkw1]

I like the foam. Needs to be able to direct water around the gussets. If it's to flat it will slam into waves.

[@NDHIZK1]

Congrats on another great milestone!

[@danleicester6875]

Stacked foam good start The new bit is square not flowing with the lines of the hull Perhaps shape foam to the square shapes on the bow sprit and the void and then fair it altogether- thus in keeping with original lines