A little more progress...
I clamped a left over cedar strip to the carbon copy sheer line and scribed a trim line. Then I used my Roto-Zip to make lots of dust and trim the excess sheer. The sheer is maybe 70% OK, but definitely has its problems. In a few spots, it's pretty darn wavy and I've been struggling with ideas to salvage the mess.
Here's a look at the trimmed shell
I know, it looks bad, doesn't it?
But wait, it gets worse, here is a look at the waviest portion of the sheer
All of the shell has really firmed up, I can tweak the overall shape slightly (must be careful to not screw up the rocker) but that sheer line may as well be cut from stone.
All is not lost, though. I think I can cut some slightly oversized foam for the gunnels. Then sand the gunnels to a smooth profile, essentially ignoring the wavy sheer partially encased in them.
Here's a look at some left over foam sections stuck on the sheer for illustrative purposes.
Sure, it's got some wiggles (foam is only resting there unsecured except for gravity and friction) but even at that width, I would have plenty of stock to work with to straighten things out. The worst portion of the sheer would be forever encased inside the gunnels, although there would still some waviness left exposed. For a first effort, and maybe a sub 25 lb build, I can live with that!
So that's the plan:
Carbon over foam bottom stiffening
A little oversized gunnels section to mask to lousy sheer
All carbon over foam gunnels, thwarts and seat frame
Oh, and for those of you keeping track, or at least wondering, I have 13 hours invested so far.
I clamped a left over cedar strip to the carbon copy sheer line and scribed a trim line. Then I used my Roto-Zip to make lots of dust and trim the excess sheer. The sheer is maybe 70% OK, but definitely has its problems. In a few spots, it's pretty darn wavy and I've been struggling with ideas to salvage the mess.
Here's a look at the trimmed shell
I know, it looks bad, doesn't it?
But wait, it gets worse, here is a look at the waviest portion of the sheer
All of the shell has really firmed up, I can tweak the overall shape slightly (must be careful to not screw up the rocker) but that sheer line may as well be cut from stone.
All is not lost, though. I think I can cut some slightly oversized foam for the gunnels. Then sand the gunnels to a smooth profile, essentially ignoring the wavy sheer partially encased in them.
Here's a look at some left over foam sections stuck on the sheer for illustrative purposes.
Sure, it's got some wiggles (foam is only resting there unsecured except for gravity and friction) but even at that width, I would have plenty of stock to work with to straighten things out. The worst portion of the sheer would be forever encased inside the gunnels, although there would still some waviness left exposed. For a first effort, and maybe a sub 25 lb build, I can live with that!
So that's the plan:
Carbon over foam bottom stiffening
A little oversized gunnels section to mask to lousy sheer
All carbon over foam gunnels, thwarts and seat frame
Oh, and for those of you keeping track, or at least wondering, I have 13 hours invested so far.