Modern Boat Maintenance.pdf

MODERN BOAT

MAINTENANCE

The Complete Fiberglass Boat Manual

Supervising editor: Bo Streiffert

SHERIDAN HOUSE

ADLARD COLES NAUTICAL

MODERN BOAT MAINTENANCE

of Johnston Co-editions, Gothenburg, and

Streiffert & Company, Stockholm, Sweden

Idea, design and production by Johnston

Co-editions and Streiffert & Company

First published in the United States of America 1989 by

Sheridan House Inc.

145 Palisade Street

Dobbs Ferry, NY 10522

First paperback edition published 1994

by Sheridan House

Reprinted 1996

First published in the United Kingdom 1989 by

Queen Anne Press. a division of

Macdonald & Company (Publishers) Ltd.,

under the title Glassfibre Boat Manual

First paperback edition published 1996

in the United Kingdom by Adlard Coles Nautical

under the title Modern Boat Maintenance

Editors: Turlough Johnston, Bo Streiffert

Designer: Nils Hermanson

Copy editor: Jon van Leuven

Authors: Dave Gannaway. Loris Goring,

Peter Milne, Dag Pike, Bo Streiffert, Jon Winge

Illustrators: Anders Engstrom, Hans Linder

Lennart Molin, Tuire Tepponen

may be reproduced, stored in a retrieval system

or transmitted in any form or by any means, electronic,

mechanical, photocopying, recording, or otherwise,

without the prior permission in writing of the publishers.

Filmset in Sweden

Printed in Italy

ISBN

0-924486-71-6 (U.S.)

0-7136-4465-6 (U.K.)

CHAPTER 1

Cockpit gratings

CHAPTER 9

THE GLASSFlBRE BOAT

Grabrails

ELECTRICS

149

General building methods

Headlinings

Electrical circuits

150

Materials

Cabin insulation

Batteries

153

Laminate moulding

Heating and ventilation

Expanding the electrical

Sandwich construction

Plumbing

system

157

Reinforcements

Gas installation

Fault finding

159

Joinings

Maintenance and care

160

Built-in reinforcements

CHAPTER 6

Alternative charging

Boat survey: the racer-cruiser 26

RIGGING

methods

162

Boat survey: the motor cruiser 30

Rigging tool kit

Installing electronic

CHAPTER 2

Rigging types

equipment

163

Masts and booms

WORKING WITH

Fastening fittings to alloy

CHAPTER 10

GLASSFlBRE

spars

SAFETY AND

The tool box

Rods and wires

MAINTENANCE

163

Repairing damage

Rigging screws and

Firefighting

166

Moulding a storage box

toggles

100

Liferafts

166

Fastening wood to

Sail-handling systems

101

Lifejackets

167

laminate

Setting up the mast

104

Maintaining and repairing

CHAPTER 3

Sailing from the cockpit

107

deck equipment

169

THE UNDERWATER HULL

Ropes and ropework

108

Dinghies and inflatables

170

Iron keels

Winter lay-up

171

Lead keels

CHAPTER 7

The boat ashore

172

Antifouling

Winterizing the boat

177

ill

SAILS

Blistering

Spring overhaul

180

Sail cloth

111

The woodwork

181

CHAPTER 4

Sail types

113

Leaks

181

THE HULL

Maintaining sails

114

Repairing damage to gel coat 54

Corrosion

183

Emergency repairs

116

~[arking the waterline

Drastic engineering

185

Painting the boot top

CHAPTERS

Emergency repairs at

Gel washing the bilge

sea

186

ENGINES

117

Repainting the hull

The diesel

118

INDEX

191

CHAPTERS

Diesel-engine fault

DECK AND SUPER·

finding

121

STRUCTURE

The petrol engine

122

Deck hardware survey

Petrol-engine fault

Stanchions and lifleines

finding

128

Fastening heavy fittings to

Cooling

130

sandwich

The exhaust

132

Fastening lighter fittings to

Air cleaner/flame trap

133

sandwich

Engine ventilation

134

Fastening light fittings to

Lubrication

136

sandwich

Rocker adjustment

136

Fastening fittings to

Starter motors

137

laminate

Power transmission

138

Non-skid surfaces

Propellers

142

Laying teak

Engine beds

144

Windows and portlights

Engine noise

145

The cockpit

The outboard

146

Cockpit drainage

Engine instruments

148

CHAPTER 1

The

Glassfibre

Boat

.1olten glass has a very high degree of viscosity,

and it is this characteristic that allows it to be drawn

IDto the form of an exceptionally fine fibre (about

ne-sixth the diametre of a human hair) and which

the basis of all glassfibre woven or mat material.

Because of glass's excellent tensile properties, it

as also come to be used as a strengthening lami-

nate in items made from synthetic resins. The plas-

resin with which the glassfibre reinforcement is

mbined is usually polyester.

One of the earliest commercial applications of a

glassfibre-reinforced laminate was the manufac-

ture of radomes for military aircraft during the

Second World War. The object was to produce a

lightweight, streamlined, protective shield for the

radar scanner. The resins used had to be heat-

cured, however, and this made them susceptible to

workshop conditions, which had to be strictly con-

trolled. Almost invariably, items of this kind had

to be pressure-moulded in matching metal moulds

and then heat-cured. This type of tooling is expen-

sive and only worth considering if the item is to be

mass-produced.

Because of the shortage of traditional materials

after the Second World War, the boatbuilding in-

dustry was one of the first to begin to produce

large, yet relatively simple, mouldings. This be-

came easier with the introduction of laminating

resins that would cure at ambient temperatures

and did not require pressure in the moulding pro-

cess. This meant that much larger mouldings could

be made and from relatively cheap glassfibre tool-

ing.

Since those days, the plastics industry has re-

fined and developed the production of glassfibre-

reinforced plastics to a very high degree, and most

modern sailing-boats and motorboats are made

from this material-and not just hulls, but also

superstructures.

A glassfibre hull is normally built up in a female

mould which is first covered with a releasing agent,

to make it possible to lift the finished hull from the

mould. The releasing agent is coated with a thick

layer of epoxy.resin, known as the gel coat, and

then with successive layers of glassfibre and poly-

ester resin.

Correctly engineered, glassfibre can produce

structures that are light, exceptionally strong, and

puncture-resistant.

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