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SageSport160 - building the hull mold

Posted: Wed Jan 03, 2018 1:51 pm
by scoob
Progress on the SageSport160’s hull mold -

The first step is to make a plug from which the mold will be made. These pictures show the hull being made in cedar strips over the form stations.
The last slat goes into the hull. This is called the 'whiskey plank' -

The hull shape is complete. Here you can see the plug and the prototype boats -

Once the strips were in place the boat was sanded smooth in preparation for a layer of fiberglass to cover and stabilize the shape.

Re: SageSport160 - building the hull mold

Posted: Tue Jan 16, 2018 1:48 pm
by scoob
SageSport 160 hull mold update!

After cedar slats were covered with fiberglass the plug was flipped over so the outwale could be installed -

Again the plug was flipped over so a flange could be installed -
The flange is needed for the vacuum infusion process that will be used in building these composite boats. Here is a link that discusses the infusion process used on the Sage 15 boats - ... -infusion/.

The plug was sprayed with Duratec, a mold surfacing and shaping product -
first layer duratec.jpg

Lots sanding was done to get the perfect shape -

The keels were installed -
and, you guessed it, the plug is again sprayed with Duratec followed by more sanding!
more duratec.jpg

More updates to come!

Re: SageSport160 - building the hull mold

Posted: Tue Jan 30, 2018 11:52 am
by scoob
Sanding … sanding … and when you think you have done enough SAND SOME MORE! The plug for the SageSport 160 is now nice and shiny and we have begun the process of making the mold!

Shinny plug that is ready for gel coat!
shiny plug.jpg

Spraying gel coat - this will be the surface of the mold.
gel coat.jpg

Many layers of fiberglass along with balsa core are applied to create a strong and stable mold. NOTE: the hull of the SageSport 160 WILL NOT be cored with balsa!!!!
skin coat of gel coat.jpg
more glass.jpg
mold balsa core.jpg
and more glass.jpg

Re: SageSport160 - building the hull mold

Posted: Mon Mar 05, 2018 12:48 pm
by sal
We're currently experimenting with different layups and different materials. We've had 2 boats out of the mold and we'll be testing them in the water this week.