Mandolin Getting Closer

Day 59

Todd: Epoxy day.  Grover came over just in time to help us measure out the
fiberglass that we will apply to the keel.  After cutting three layers to
fit we stacked them carefully in order.  Then starts the process, wet out
the keel with straight epoxy, press the glass against the epoxy, wet it
out with more epoxy, squeegee out the excess, then wait for it to
partially dry.  We repeated this for each of the three coats then brushed
on an over coat of slightly thickened, with 406 colloidal silica, epoxy.
While it doesn't sound like much it took us the whole day, and a full
gallon of epoxy.  Grover was a huge help as we needed extra hands to help
hold up the glass while we wet it out.  We were joking that if Grover
weren't their we would have gotten out of control and started slinging
epoxy coated glass at each other, eventually one of us would finally win
by epoxying the other to the keel under three layers of wrinkly glass.
Thanks Grover for keeping us sane.

Day 60:

Todd: Now that the epoxy on the keel has dried we wash it off with water,
soap and a scotchbright pad.  The rest of the day we spend sanding the
overcoat down smooth.  We almost finished.  During all this, Omar is
busily fairing away on our most recent pass of filler.

Day 61:

Ellen: March 16th, nine years ago today, Todd and I began dating.  We had
known each other for about three months before I pinned him down and
kissed him.  We always celebrated this day as our anniversary before we
married, but had neglected it once we had a wedding anniversary to
celebrate.  This year we made sure to celebrate the beginnings of our
relationship.

Unfortunately, it began badly.  At 5:30 I woke up to go potty.  Todd got
up after me.  I felt the boat shake a bit as Todd was getting out of bed,
which normally doesn't happen.  The boat usually shakes a bit when someone
is sanding strongly or when someone is climbing the ladder.  Usually the
ladder bangs a bit on the toerail of Mandolin when someone begins climbing
the ladder.  I heard no sound, just felt a slight shake of the hull.  It
was enough to make me notice, but not enough to think much of it.

However, when Todd was done on the toilet, he happened to glance toward
the cockpit and saw the shadow of a man entering it.  Not being fully
awake and not expecting anything out of order, he thought it was the new
night guard looking around our boat.  He went to the companionway and
said, "Hola."  The man ran down the ladder and ran away from Mandolin
accompanied by another man.  Todd informed me that two men had just
climbed our ladder while he quickly dressed to investigate.  Rather
disquieting information when your a woman naked in your bed.  I dressed
and joined Todd.

The only items missing were our Teva sandals and a pair of my tennis
shoes.  They were at the bottom of the ladder leading up to our boat.
Instead of being scared by the intrusion, I became immediately angry that
items had been stolen from us.  We went to find the night guard.  We found
him sleeping.  We woke him and told him, in Spanish, that two men had been
at our boat and our shoes were gone.  There is a boatyard dog that was not
in the boatyard that night.  The guard asked where the dog was.  I was so
angry that he had been sleeping, allowing intruders to enter the less than
secure boatyard.  I yelled and cursed at him that it wasn't the dog's job
to watch our boat.  I don't know when I have ever yelled at a stranger.
But how dare he sleep when he is paid to guard the yard?  He called the
police and we woke the other people living on their boats.  Turns out that
the intruders had boarded these other two boats, as well.  The morning was
dewy and footprints could be seen in their cockpits and on one of the
boats, all around their decks.  They were very quiet as Annie had felt her
boat slightly shake, but did not hear them walk all over her deck.  Scary.

What is also scary is that nothing else was taken but our shoes.  We think
they were looking the place over to see what they could haul away at a
later date.

So we met the yard manager at the gate when he arrived at 8:00.  Todd had
already filed a report with the police when they had arrived earlier in
the morning.  We told him what happened including that the guard was
asleep.  The guard denied it, but we pointed out that there was evidence
that the intruders had boarded three boats and the guard most likely would
have seen them if he were doing this job.  After we got across just how
angry we were, the manager agreed to pay half the retail value of the
three sets of shoes and to increase security.  And then I let my anger
pass away.

Rick, the captain of Cutwater, had just returned the day before from a
several day charter.  We told him our woes and then I begged a cup of
coffee.  He had lots of wonderful fruit left over from the charter, so we
chowed down on coffee, fruit and sweet bread.  Just the solace we needed
after a stressful morning.  And we agreed to have a potluck dinner that
night aboard Cutwater.

Having planned to make our special day a day off from the boatyard, we
headed into town.  We couldn't avoid being practical, however, and managed
to fit in several errands in between fish tacos, ice cream and fresh
squeezed orange juice - a BIG glass was only $1.00.

We made it back to the marina just in time to take a shower, get pretty,
and catch sunset on Cutwater.  Our friend Anne and her visiting friend
Sandy went diving today and contributed a huge calimari steak to dinner.
We had a great evening filled with friends and fun.  Rick, Anne and Sandy
proceeded to get rip-roaring drunk.  I'm glad I gave up alcohol until
Mandolin is back in the water, or I would have joined them.  It was more
fun to stay sober and watch them get stupid.  A bad beginning, but a
terrific ending is much better than the other way around.

Day 62:

A fairing we will go!  A fairing we will go!  High ho the merry-o, a
fairing we will go!

Not only did Grover show up to help us fair, but our new friend, Ethan,
from Gypsy Dolphin also came to help us sand and fair.  Are we fortunate,
or what?  It was a big fairing day on Mandolin.

In the evening, we got together with our marina friends, Stephanie, Kyle,
Rick, Anne and Sandy for pizza.  Luckily, we decided not to go into town
for it.  Stephanie looked at Todd and said that she didn't think it
possible to fall asleep with your eyes open, but he was proving her wrong.
We went home to bed when we were done eating.

Todd's arms were really sore, so I massaged them and then we fell asleep.

Day 63:

Woke up at 5:30 to answer the call of nature.  Todd woke up, also.  As I
was trying to go back to sleep, Todd mentioned that his arms sure felt a
lot better than his back, which was rather sore.  I decided I probably
wouldn't fall asleep again, so I got back out of bed and started Todd's
day off right with a back massage.

Anne, Sandy, Todd and I mooched another coffee and fruit (yes, more left
over fruit) breakfast from Rick.  A French bakery opened in the marina, so
Todd and I supplied a loaf of still hot, not warm but hot, loaf of bread.
Good friends, food and coffee sure make boatyard life a lot more bearable.

Gee, then what did we do?  Oh, yeah.  We faired some more on Mandolin's
hull.  Grover again rode his bike over to help.  I think he's trying for
sainthood.  We faired and sanded and faired and sanded and, and, and
then.... we were done!  Mandolin's hull is smooth!  We are planning to
apply the barrier coat primer in the morning.  I am so happy and so tired.
I'm so tired, I'm about to fall asleep at the keyboard.  Anne came over a
little bit ago and I grinned from ear to ear about our smooth boat bottom.
It felt so good to smile really big because I felt so happy.  Tim drove up
from Cabo to spend the night.  He took us out to dinner in celebration of
our recent anniversary and birthday.

Day 65:

Todd:   We have been looking forward to getting Tim's official opinion on
whether Mandolin is fair enough or if we need more.  We respect Tim's
opinion since he has done two blister jobs and we were pleased when he
announced that we had done a fine job fairing and he even wanted to know
we did the turn of the keel (where the keel meets the hull) which is the
most difficult area to do.  Of course there are a few ripples and valleys
if you look close, but as he puts it: Don't let the perfect get in the way
of the very good.  To celebrate we went to Tecolote, which is a beach at
the north end of the peninsula we are on.  We had grilled fish under an
umbrella while watching the turquoise waves lap against the beach.  Just
what we needed after all the fairing we have done.  In the afternoon we
went with Rick and other friends aboard Cutwater to go out and anchor.
The main purpose of the outing was to test the watermaker and test the
crane that lifts the dinghy aboard this beautiful 55-foot motor vessel.
Of course we had a BBQ, went swimming and just had a wonderful time in
addition to these two chores.  Oh, guess we forgot to mention that we are
taking the day off today.

Day 66:

Todd:  Today is the big day: Apply the primer coat.  We are using Interlux
1000.  The first step is to clean the hull with soap and water, then with
the Interlux solvent wash.  This is similar to paint thinner or acetone
where you wipe it on with one rag and wipe it clean with another rag,
changing rags often.  We then mixed up the 1000 by marking some mixing
buckets, 2.5 cups and another 1 cup to get the 5:2 ratio of base and
hardener.  Once mixed, we brushed the first coat on, then squeegeed it to
force the epoxy into any small voids and scratches.  We quickly discovered
that we had mixed too much epoxy to apply in the 20 minute working time.
Especially since it was a warm day out and we had even less working time
before it started to harden on our brushes.  So we switched to mixing half
that amount: 1.25 cups of base to .5 cup of hardener.  This was a more
manageable amount.  We also learned that it was better to roll the fist
coat on instead of brushing, but still use the squeegee to force it in.
Once an area was done we would come back and roll on another coat before
it dried, then tip it out with a foam brush so it was smooth.  About this
time, Grover showed up to help out.  Again, wonderful timing as it was
really nice to have one person rolling, one squeeging or tipping and one
mixing epoxy or assisting the other two.  Between the three of us we were
able to finish the hull around 3:00.  Things went very well and we got
better at the application as we went.

The rest of the day was spent at Cutwater where I helped Rick clean the
membranes of his watermaker and work on the crane that lifts their dingy.
While we made some progress on the watermaker, it still isn't producing
drinkable water.  Ellen came over and baked banana bread and a dinner of
salad and quesadillas.

Day 67:

Todd:  In large red type the Interlux manual says: After the Interprotect
has cured for 4 - 24 hours, scrub the surface with soap and water to
remove chemical blush or sweat...  So we did just that, We have found that
using 3M scotch bright pads and soapy water does a better job than a
brush.  If the water doesn't bead up on the surface you know that it has
been washed enough.  After breakfast, we started the task of sanding the
entire surface with 80-grit sandpaper.  We made terrific progress, but
were only able to finish 3/4 of the hull before we couldn't hold the
orbital sander up any more.   We are really glad we had faired as much as
we had since this job would be much more difficult on a bumpy hull.  Our
challenge has now shifted from getting a fair hull to getting rid of all
the pinholes.  These are small holes or voids in the hull.  They are bad
since the barrier coat won't fill them.  These pinholes will allow water
to enter through the bottom paint into the hull, rendering this whole job
somewhat worthless.

The goal is to get rid of every one of them.  One thought is to just goo
the barrier coat in the holes, but the preferred way is not to have any
holes when we start the barrier coat.  So it looks like another pass with
the primer coat should take care of them.  Just add another two days to
our time in the yard.  Drat!  Actually this should be time will spent.

Day 68:

Todd:  We finished the last bit of sanding by noon today.  Grover and
Ethan offered to come over to help with the second coat of primer.
Unfortunately after they arrived the wind really picked up.  This is the
norther that they have been predicting for the last couple of days.  The
wind isn't that big of a deal for the primer since it is much like epoxy,
but when dust is blowing through the air it is too much.  So we decided to
push off doing a primer coat until tomorrow morning.  Instead we started
stripping the paint off our dinghy so that we can glass and repaint it.
They were a big help and we made quick work of it with the three of us.
Ellen went to town to get us some food since we were running low.  After
Ethan left, Grover and I finished drilling the thruhulls that still needed
doing.  So now we are just hoping for nice warm windless days until we are
done.  We'll see since northers typically last a few days.  At least it's
not snowing and raining like it is in the states.

Day 69:

Ellen:  We applied another coat of Interlux 1000 primer this morning.  At
4am we woke up to no wind.  We briefly thought about applying primer with
the worklight, but then reconsidered when we realized the day might become
dewy at dawn.  So we went back to sleep until first light at around
6:30am.  The day dawned windless and dewless.  Perfect.  On with the
grubby clothes and out with the supplies.  After a quick breakfast, we
were applying 1000 by 7:15am.  Ethan came around 8:15 am and we were all
done by 9:30 am.  Woo hoo!  Time for coffee, croissants and rolls at the
French Bakery.

A build up of fatigue from all the work we have been doing caused me to
curl up with a book and ignore the world for the rest of the day.  Todd,
however, still had energy and sanded more on the dinghy.  He also mounted
backing plates for all the thruhulls with thickened epoxy.  We were
planning to wash and sand the 1000 primer, but because it was a cooler
day, it didn't set up as fast.  We decided a full day of curing would be
best.

Day 70:

Ellen:  Wow!  Hopefully we won't get into the 80's, as in Day 82...

Washed and sanded the hull this morning and early afternoon.  Well, Todd
did most of it while I went into town for more supplies and food.  I think
my job title should be Gatherer Chef, with a subtitle of Jill of All
Trades.

This afternoon, while I did laundry, Todd worked on removing the tape
residue at the waterline.  We had taped the waterline before we left the
boat last May so the yard workers would know how far up to grind off the
gelcoat.  Eight months of heat and sun caused most of the adhesive to
remain on the hull.  As well as remove the adhesive, we are also trying to
clean the gelcoat before we apply the barrier coat and bottom paint.
Rubbing compound and elbow grease didn't do the trick, so it looks like we
will be buying some fine grit sandpaper tomorrow.  Wow, you mean they make
sandpaper finer than 80 grit??  That's the finest we've used in the last
two months.

Day 71:

Ellen:  If this were a newspaper, today's headline would read: "High
Excitement In Boatyard; Mast Breaks, Two Fires"

Well, before you think poor Mandolin had a rather rough day, let me assure
you that Mandolin and her crew were innocent bystanders during most of the
fun.

We spent the day sanding, applying rubbing compound and waxing the gelcoat
above the waterline.  Around noon, our worker, Omar, got called off our
boat to help take a mast off of another boat.  Time for lunch aboard
Mandolin.

We watched from Mandolin as the workers hooked a crane up to a mast
several boats away from us.  Hmm, they're connecting some kind of line
from the crane below the lower spreaders of the double spreader mast.
Looks like the crane is attached to the mast below its center of gravity.
As the crane lifted the mast out of the boat, the mast began to lean a
little.  The owner and a worker were standing at the bottom of the mast,
perhaps helping to guide it out of the boat.  The mast lifted free of the
boat and then slowly swung from vertical towards horizontal.  This was not
part of the plan.  As the mast neared horizontal, and swung toward another
boat's rigging, it rotated and struck one of its spreaders on the crane.
With the support of its rigging compromised, The wooden mast then
proceeded to break in two near where the crane was attached.  What had
been nearly horizontal now broke in the middle and the two ends crashed
toward each other in opposite arcs down toward the deck of the boat and
the men standing there.  Amazingly and luckily, no one was hurt.  There
was enough rigging on the mast to still hold the two parts together and
suspend them from the crane.  Listening to and watching the wood break
apart and then swing down out of control towards men and boats was a
sickening experience.  I became nauseous and bend over double.  It is
definitely one of the worst things I've ever seen.

Todd and I scampered down the ladder, put our shoes on and hurried over to
make sure medical assistance wasn't needed.  It wasn't.  We went back and
continued working on Mandolin.

About an hour later, Todd saw the guard, who had been sitting near our
boat, jump up and run away.  When Todd looked in the direction he ran, he
saw smoke rising from the deck of a trimaran.  This trimaran has been
having work done on it for the last several weeks.  Soon he saw the cloud
of a fire extinguisher.  Next came the brooms to sweep away the dust and
then came the paintbrushes to hide evidence of the fire.  Have we
mentioned you should always supervise work being done on your boat?  This
is an example of why.

Hey, the fun doesn't stop there.  Not two minutes later, three young
Mexican men on the sidewalk outside the boatyard behind Mandolin's transom
were waving and trying to get Todd's attention.  They asked if he spoke
Spanish and then excitedly directed his attention to a four foot row of
bushes that were on fire with about foot high flames.  Yikes!  Out with
the hose to douse the flames.

Masts falling down, fire on two sides of Mandolin...  Time to get out of
the boatyard and back in the water where Mandolin belongs.

Day 72:

Ellen:  Well, happy day!  There are four coats of barrier coat on
Mandolin's bottom.  Hurray!

We woke up at 6:30 to wash and sand and solvent wash and tape, and then
barrier coat.  We started barrier coating at 10:30am and finished around
6:30pm.  We have three more coats to do tomorrow.  We need to wait two
hours between coats, but have as long as sixteen hours before another coat
must go on or else it's time for the dreaded sandpaper.  I imagine sanding
that could have been avoided being something like having tea with the
Wicked Witch of The West:  "Hello, my pretty.  Come and play with my sand
paper."  The appropriate cackle would then follow this remark.

Okay, tip for the day: Put two layers of tape at your waterline when you
paint, or buy two-inch tape.  We still went over the tape onto the gelcoat
a few times even with this precaution.

Our friend's on Cutter Jones are out of town, so we are sleeping on their
boat tonight as ours has toxic fumes.  Cutter Jones has three black cats
on their boat.  If I weren't so tired, I'd be wondering if I'd get any
sleep with these three playful monsters...  We are wiped out.  Time for
bed so we can be up at 6am.

Day 73:

Ellen:  Happy day!!  Up at 6am and three more coats of Interlux 2000 on
Mandolin by 1pm.  Hurray!  We are done with barrier coating.

This afternoon, Todd napped on Cutter Jones while I went to town with
Anne.  The ice cream was great, but I should have napped.  By 7pm I was
wiped out.  We had a movie night on Anne's boat and finished watching
Horatio Hornblower.

We can't sand the barrier coat for 24 hours.  Darn, a forced break :)
Tomorrow afternoon we will be sanding and then applying our first coats of
bottom paint.  It's all down hill from here!

Day 74:

Ellen:  We couldn't sand the barrier coat until 1pm, so we took it easy
and then worked like dogs all afternoon and evening.

Our days have been starting out right with coffee and tea aboard Cutwater
with our friend Rick.  This morning was no exception.  He just returned
from a short trip to the states and was able to pick us up two new pairs
of sandals to replace the ones that were stolen.  Mine fit great, but
Todd's were a bit big.  Luckily, our friend Anne was flying to California
for a week and was willing and able to exchange them for us.  Sure is
great to have good friends.

At 1pm, the work began in earnest.  We sanded the entire hull.  Happily,
the Interlux 2000 is easy to sand.  Very similar to bottom paint.  We took
breaks from sanding to seal in our five thruhulls.  Or rather, in between
sealing thruhulls, I continued to sand.  While Todd scraped and sanded
away the excess sealant from the thruhulls, I mixed the bottom paint.
When I started bottom painting, Todd taped the waterline.  It was after
6pm by the time we started painting.  The sun went down at 6:30pm.  By
using a worklight, we were able to finish painting the first coat over the
entire hull and paint a second coat around the waterline by 8:15pm.  We
painted these first two coats green and this will become our bootstripe.
Tomorrow we will retape 4" down to paint two coats of blue bottom paint.

Halfway through all this work, in the late afternoon, I said to Todd,
"Well, I hate to say it, but I think you need to take me out to dinner
tonight."  We thought we would be done by 7pm and had thoughts of going
into town.  We weren't done till after 8pm and were too wiped out to even
consider town.  There are three restaurants at this marina.  We decided to
try something new, so we went to the Italian restaurant.  After a too
expensive meal of fabulous food and good ambiance but zombyish company,
our sanity levels went way up.

Day 75:

Ellen:  Retape and paint; easy, right?  Painting was the easy part, but
getting tape straight around the boat is an art form.  As budding artists,
it took us only 4 hours to measure, mark and retape the boat.  Oof.

The difficulty with retaping is that it is best for the bootstripe (the
stripe of paint just above the water) to be the same vertical distance all
around the boat.  However, the hull angle is more pronounced at the bow
and stern than at the sides of a boat.  The reason you want the same
vertical distance all around is that when people look at the paint
straight on, it will look the same width.  If you simply painted the same
width paint all around the hull, the paint would appear to be thinner
where the hull angled more away from vertical.  To get the same vertical
distance where the hull goes in as well as down is tricky business.

First we had to find the right tool.  We need to measure exactly four
inched down and varying inches in towards the hull at exactly a 90-degree
angle.  We needed an adjustable right angle.  I could envision the tool,
but didn't know if it existed.  When I described it to Todd, he said we
also needed a level.  Funny carpenter levels usually aren't found on boats
where almost nothing is level, square or symmetrical.  Todd and I had
vague notions that we might just have a right angle.  Todd went digging in
the tool compartment and came up with not only a right angle, but a
sliding right angle WITH a level.  Hey, hey must be our lucky day.  That
was the easy part,

Then came marking the hull with this tool, a ruler and a pencil.  That was
the tedious part.  Then came actually taping as straight as possible for
both sides of a 34-foot boat.  This was the difficult, major
concentration, and wow-my-eyes-really-hurt part.  And just four hours
later we were ready to paint.  And after lunch, we did.  Compared to
epoxying, fairing and barrier coating, bottom painting is the candy.
Bottom paint goes on fairly easy and you know you're almost done with your
tedious, awful bottom job.

Day 76:

Rick had told me last night to knock on Cutwater when we were ready for
coffee.  He's been a little sick and we woke up at 6:15am.  Hmm, probably
a little early to wake him up.  We decided to get our last coat of bottom
on before we woke him.  By 8am, Mandolin was looking good and now we could
really enjoy the rest of our morning.

While I went to the grocery store and bought $100.00USD worth of food (I
shared a taxi with Rick), Todd cleaned, sanded, solvent washed, and
epoxied Mandolin's bilges.  To say he was tired by 5pm is an
understatement.  While Todd slept for two hours, I prepared food for the
next several days and cooked a really good cauliflower potato curry for
dinner, which we shared with Rick.

Day 77:

Another milestone: the stands and blocks have been moved under Mandolin.
This involved having the tractor and trailer that moves boats in the yard
come and pick Mandolin up off the blocks under her keel and move them all
to areas that are finished with bottom paint.  The areas that were under
the stands are still bare fiberglass.  The areas under the blocks still
had gelcoat, which needed to be ground off.  So we need to do the entire
process of primer, barrier coat and paint for each of these areas and the
rudder.

We had a bad scare today.  Todd was lying on this back under Mandolin
grinding the last bit of gelcoat off the bottom of the keel.  He had put
plastic garbage bags between the blocks and the boat to keep the new paint
from getting dinged.  The 5" Makita grinder he was using snagged one of
the plastic bags then ripped out of his hands.  Fortunately it was thrown
forward away from where he was laying before it hit the ground and was
spinning out of control.  The grinding disk is thin, sharp and spinning at
10,000 RPMs would have no problem gouging its way deep into human flesh.
Luckily, Todd was able to roll and scramble away from the grinder and then
unplug it without getting hurt.  He was really spooked, though, and
decided he was done with work for the day.  While Todd napped, I sanded
the areas where the pads had been.  This was done the safe and slow way by
hand with a piece of 80-grit sandpaper.

-Todd and Ellen


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