Making a Fiberglass Mold: A Year of Work | Windpuff's Rebuild [S1 Ep4]

[@JOHNALOOPONE]

I keep coming back to see this because. Every man should build a monument in fiberglass. Good work congratulations on family. Just cut off anything that does not look like what you had in mind. Also get indignant when people doubt Your ideas. It will not change a thing but makes Them go away.

[@RiggingDoctor]

It’s about ready to pop out of the mold and I’m so excited!

[@SailingThruLife]

Congrats on the baby. That's awesome. Parenthood is a whole new adventure in itself.

[@RiggingDoctor]

It really is!

[@jimkilgos1444]

Thanks for this video guys I've been working on a similar project and my Admiral has been confused on why I have been working so much but not making any progress....l can now show her that the finished project is not magic....l actually lagh wifh you at the end as the conversation was identical to my conversation at home... Also Herbie.... congratulations on the birth of your son

[@RiggingDoctor]

Thank you :)

[@seanflanagan2441]

Oh wow! Folks, I am so very happy to learn of your "expansion", and delighted to see the progress made to make a mold for the expansion of Windpuff. A very sincere,"Thanks" for the update - all the news. God bless you all, and keep you in His embrace!

[@jasonmcintosh2632]

Wow. That's a lot of work. Looks like you're doing a great job. Enjoy the process.

[@kennethzielinski6233]

Congratulations!

[@jerylabrams8408]

I love your creativity, this is trial & error! You have the best intentions and the Alberg is so versatile, will be watching your ideas, how you make this happen. We watch Matt on Duracell doing his fiberglass work , as well as Sailing Melody. Looking forward to seeing you rock this project!💕👍😎⚓️⛵️

[@RiggingDoctor]

😎👍

[@OMIF1]

Merry Christmas

[@russking63]

The end was hilarious. She was being so kind, but probably thinking, "Oh, God. Now what?" That's trust right there. Merry Christmas!

[@RiggingDoctor]

She was being so kind! She even said it looked nice 🥺

[@musicisbrilliant]

This is SOOOOOOOOOOOOOOOOOOO COOL. Such a big undertaking. I love watching your process. This makes me think about doing the same thing. Im the guy with the old ericson 35. SURE WOULD be nice to have more room for more solar panels!!

[@retovonniederhausern8423]

So good you put the whole scene in the video from the moment maddi sees the 'finished thing' all the way to the '...oh'☺️

[@vaidotasratkus7619]

I only worked with polyester once in my life, it stinks a lot. Afterwards I switched to west systems. BUT the way you approached this project is 100% efficient. The type of glass fiber you chosen the type of resin is absolutely biggest bang for buck.

[@davecopp9356]

That was funny. All the best and congrats on the baby.

[@svphoenixandme776]

It's your boat. Build/do what you want to with it. Was grinning at your description of the amount of time spent fairing. I put in about 2 1/2 years fairing a home built double chined 38' steel hull. I feel ya. Wait tiill you're fairing it as part of the boat. Advice on large hull fairing... Don't buy the Flexisander sanding boards. Nothing wrong with them at all. But their fairing board/knife with adhesive backed Aluminum Oxide sandpaper on it is Amazing. The adhesive is the only drawback. Heat gun to effectively remove the sandpaper and gasoline to remove the remaining glue residue. Probably a better way. But that's what worked for me.

[@lenwhatever4187]

Pattern making is an art all to itself.

[@RiggingDoctor]

Yes indeed!

[@theromihs]

Congrats guys!!!

[@PyeGuySailing]

The amount of work done on just the mold is staggering. You are to be commended.....or committed lol ;) Amazing tip about the Elmer's glue, that will be very useful to me. Happy holidays guys I hope you get to spend lots of time with family and friends.

[@RiggingDoctor]

I think the latter is more appropriate 🤪 If I had to do it again, it would go much faster because I know how to work it now. At the time I was learning while doing which isn’t always the fastest way about it

[@SailingSisu]

Wow, what an incredible journey you've been on in rebuilding Windpuff! The amount of effort and dedication you've put into making this fiberglass mold is truly inspiring. Remember, all the hard work will definitely pay off in the end. Keep up the great work, and as always, your attention to detail and craftsmanship is top-notch. Well done!

[@RiggingDoctor]

Thanks! It has been a huge process and it fails like we are almost done when we still have so far to go

[@wahme]

I have faith in you, Herbie. I'm pretty crafty, myself, and I can totally see it happening. I know you won't let the sceptics slow you down. My marina neighbor being on naysayer. Congratulations on y'all's new baby boy! Happy New Year to your new fam.

[@mjproebstle]

All of the planning and effort will be worth it when the new extension fits like a glove, and becomes the essential part of the stern. Cheers, and Merry Christmas 🎄

[@RiggingDoctor]

Thanks! It’s going to be a lot of work but I won’t stop until it blends right in with the boat

[@jamesbennett5548]

Awesome progress. Congratulations on your baby. Love your channel, such a great couple and wonderful sailing content. Your blessed 🙏

[@RiggingDoctor]

Thank you very much 😊

[@bobcornwell403]

Congratulations on completing an incredibly complicated project. Merry Christmass.

[@NeilMartin-z7e]

Great work congratulations

[@graeme-sailingskeptic]

Maddie’s reaction 😂 perfect

[@RiggingDoctor]

Indeed

[@erichaskell]

I purchased a home that once had smooth drywall which was wallpapered. The previous owner removed the paper, painted the walls but had done nothing to repair the wall of all the gouge marks from the process of removing the paper so....I learned how to make the walls ultra smooth. This is fairing on a large scale but like you, after filling and sanding and filling... there came a point where you just had to stop as the process got more and more tiny and working more would be an effort in futility. So, I get your pain.

[@RiggingDoctor]

Diminishing returns for increased effort

[@sailorstu]

It's looking much better Herbie, If you haven't started laying the final product yet, may i suggest trying Vacuum Bagging. It may work for you but then again it might not. It's basically laying out the glass, then wrapping everything in airtight plastic sheeting and sucking all the air out Thes pulls everything tight against the mold rather than using blocks to hold it's shape. As a side benefit it turns out becoming much smoother reducing sanding. I have honestly never tried it, but will be using it with my next project.

[@RiggingDoctor]

I looked into it briefly because it would have fixed my air bubble problem, but it was a lot of extra equipment setup that I did not have on hand, so I just worked on doing a better job. I do really like the way it works, pushes nice and evenly on every surface to make the strongest layup possible with no resin rich areas.

[@johninerie9251]

Very nice work

[@michaelhicks3909]

Wow

[@RiggingDoctor]

It’s a projects!

[@svjaydenmarie4450]

That's so awesome I would have had the same reaction she had I did on a couple things while we were doing our reset before we moved on to our boat Merry Christmas to your crew from ours.

[@RiggingDoctor]

Merry Christmas!!

[@SailingAndInvesting]

Make the positive to make the negative so you can make a positive. Got it. Nice. Love the time lapse. Now you can make lots of positives. Was that a laugh or cry at the end? Haha

[@RiggingDoctor]

It was a bit of both 😅

[@chhindz]

Parley revival made some hull extensions.

[@RiggingDoctor]

I should talk to him next time I see him at the boat show

[@colinwinters6140]

Hey guys just remember. It WiLL be worth it!!!

[@RiggingDoctor]

👍

[@DowneastThunderCreations]

👍👍👍

[@RiggingDoctor]

Thanks

[@pirateroberts4411]

Congratulations guys! Quick rigging question: do you do consulting on it? I thought i remembered you mentioning it but couldn't remember for sure. Thanks' so much!

[@RiggingDoctor]

I do consults. Please email me at [e-mail] and we can go over the details.

[@clivestainlesssteelwomble7665]

Merry Christmas you guys 🎅🏼🇬🇧🧙‍♂️ one reason why they still build boats in wood..and metal...lol.

[@RiggingDoctor]

Indeed! Build it once and be done instead of building it three times to be done 🫠

[@clivestainlesssteelwomble7665]

@@RiggingDoctor Really you'd only want to do it if you were going to produce a line of identical boats or parts . To get serious for a moment the moulded fiberglass or composite hull is a bit of an issue in boat building as it limits flexibility. A notable designer builder who escaped this by building sandwiches on flat tables was the late Uk/Welsh later NZ designer and pioneering builder of race boats and Trimarans Derek Kelsall. kzbin.info/www/bejne/o3XNfXVupdOeedUsi=fvEO9t1tUxRfjrvT

[@jageryager]

Nice mold! I saw in your drawing you have the backstay back on the new transom. Is that how you plan to rig it?

[@RiggingDoctor]

That has recently come up for debate. Apparently the Alberg has a slight issue where a crash gybe in a storm will cause the boom to rip out the backstay and take down the mast. I am now looking at options to extend the structure to relocate the backstays.

[@RiggingDoctor]

We will answer this question in our live video tomorrow at noon!

[@melinda5777]

Ok, LOL, MERRY CHRISTMAS Y'ALL!! 🙏❤🇺🇸⛵👣🤗⚘⚘⚘

[@RiggingDoctor]

🎅🏻

[@johnlcallaway]

Thanks for the update!! Looking good!

[@RiggingDoctor]

Thanks 👍

[@bryrensexton4618]

👍!!!

[@RiggingDoctor]

Thanks!

[@anthonyrstrawbridge]

👍🏼👍🏼

[@sailingmoonshadow3169]

Haha, Saran Wrap - see my comment on the last video that I watched right before this one! Anyway, nice job Herbie, I guess you'll have the new piece installed by next Christmas 😉. How do you plan to attach it and have it strong enough to support two people and, perhaps, a backstay?

[@RiggingDoctor]

Lots of fiberglass tabbing as well as structural components to tie it all together

[@ctndiaye1]

What is the purpose of the extension?

[@RiggingDoctor]

Strong stern anchor mount, protect the windvane, boarding area, more space for solar panels.

[@RiggingDoctor]

We will answer this question in our live video tomorrow at noon!

[@johnbolongo9978]

I think a match and lighter might be an appropriate Christmas gift.....

[@RiggingDoctor]

That’s mean 😢

[@kidonaboat]

I'm wondering why you couldn't have just built the extension on the boat without a mold?

[@RiggingDoctor]

Trying to get the curves around the windvane would be challenging. Also, working at ground level on an upside down part is easier than working upside down 8 feet in the air!

[@shopart1488]

Maybe a bigger boat would be easier. Plus this needs to be ocean crossing ready.

[@RiggingDoctor]

We already have a bigger boat. This is purely for the fun and challenge of the project.

[@z_actual]

gezus I need a drink something fierce ...

[@RiggingDoctor]

🍻

[@MindBodySoulOk]

Confused as to why all the molding when you built a nice looking piece FOR the mold.

[@RiggingDoctor]

The nice piece was not structural, it was purely for space reasons. It’s much easier to build a good structural piece at ground level than 8 feet in the air! This lets me make it right and then attach it

[@RiggingDoctor]

We will answer this question in our live video tomorrow at noon!

[@caparchmar4010]

We love your video keep on !!!

[@RiggingDoctor]

😊

[@BIBIWCICC]

You will tear out your original transom when you have a heavy following sea.

[@RiggingDoctor]

Not if I make it right

[@RiggingDoctor]

We will answer this question in our live video tomorrow at noon!

[@bfett68]

sweet mother of god

[@RiggingDoctor]

It is impressive

[@Ostrichpeopletrolling]

😂😂😂❤

[@jeffgriglack9624]

So, I don't remember you mentioning the most important part: What's the baby's name?

[@RiggingDoctor]

Harry :)

[@svveritas9704]

Sniffing too much polyester resin

[@RiggingDoctor]

🥴

[@danratsnapnames]

bro. that foam doesn't care about the resin. i've used MEK with that squirt foam and never had issues. you have problems with different types of foam.

[@RiggingDoctor]

Areas where the Elmer’s wasn’t perfect dissolved away. Thankfully the other areas supported the glass so it wasn’t too much work to fair out the sagging spot.

[@Hotzenplotz1]

Way too much effort and plastic waste. And the pattern doesn't fair to the boat, there's a negative knuckle at the joint and several inside the mould. You can't do the rough fairing apart from the boat. This could have been much easier, environmentally friendly, cheaper and faster. It's easily possible also for beginners to fair the foam on a positive mould in a way that addresses the thickness of the laminate. Or make a negative mould directly on the stern of the boat with battens and thin bendable plywood. Hope you will use Epoxy and woven glass instead of polyester and chopped mat on the actual piece. EP glues a lot better to Polyester and makes a lighter product possible. Weight is important to save at the ends of the boat for seaworthyness and comfortable behavior. I'd do it with vacuum laminating to achieve as low weight as can. Makes it stronger as well as the amount of resin is reduced and only the glass makes it strong. Resin holds only the fibres in place.

[@RiggingDoctor]

You would also need to use nomex coring to get that weight level achieved.

[@Hotzenplotz1]

@@RiggingDoctor No, Balsa or Foam Battens could be used as well.

[@RiggingDoctor]

We will answer this question in our live video tomorrow at noon!

[@Hotzenplotz1]

@@RiggingDoctorThanks, I don't have any questions regarding this. I know what I'm talking about.