Duracell project: Reconstruction of a hull bottom shell


Modifications to the layout of the Duracell racing yacht to transform it into a cruiser are not without consequences for the structure. After a major sanding session, Matt had to rebuild some of the hull structure's keels, partly using salvaged components.

Boat preparation and perseverance

This week's episode of the Duracell project begins with a long sanding session, which gives Joni the opportunity to underline Matt's perseverance. It's also a good opportunity to remind Matt of his protective habits, with overalls, cartridge mask to be replaced regularly, and gloves to be worn, Matt going so far as to store them for waterproofing.

Structural stratifications

Before starting work on the quarterdeck and watchstand, Matt has to finalize the structural work in the area. After filling the large gap between the new coachroof and deck with filled epoxy, Matt lays out the interior. He opts for two glass bi-folds, remembering that the lower fabric must be wider than the one above.

Cutting out the ballast tanks interrupted the boat's longitudinal structure, as its walls were an integral part of it. The remaining foot of bulkhead was insufficient to stiffen the hull bottom, so Matt reconstructed a U-shaped hull using pieces of sandwich bulkhead cut from previous work. He then drapes the U with unidirectional carbon fabric on the sole of the U, encapsulated in bidirectional glass fabric all around

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