roving. Unidirectional roving is again used on this part in areas
subject to stress cracking.
Bulkhead bosses are filled with a microsphere and resin mixture for
further stiffening.
The deck and headliner are pressed together in a jig with a resin and
microsphere mixture used as a bonding and compression matrix in areas of
high loading.
After the microsphere mix has cured, the combined unit is pulled from
the mold and delivered to the deck hardware department for attachment of
wood parts and hardware.
BALLAST
The lead ballast is cast and mounted inside the keel cavity of the hull.
The ballast set is composed of three individually cast pieces each one
of which is checked against an optimium weight and matched with others
to produce the correct total weight.
Each side piece stradles the section of fiberglass CD pin tubing
extending from the trunk to the hull on its side, and the forward piece
butts up to the forward end of the side pieces. Each piece is checked
for proper location horizontally and vertically before it is set in
place.
The ballast is bedded in a mixture of special low shrink resin and
microspheres. This bedding acts as a shock loading barrier between the
keel and the ballast as well as an adhesive to bond the ballast in place
and seal the centerboard tubes.
The ballast is leveled and then covered with several layers of glass
cloth running up on the hull on each side. Upon curing the bilge,
ballast, and area below the cabin floor is painted with a beige gel coat
for ease of cleaning.
RUDDER
The rudder assembly is comprised of two molded fiberglass half shells
bonded together with the rudder shaft and gudgeon insert glassed in
place.
A solution of microsphere and resin is poured into the assembled half
molds and allowed to cure to full hardness.
Once the rudder is removed from the molds, it is glassed and faired
along its edges.
The bronze gudgeon casting is imbedded in the bottom of the rudder to
accept the bronze pintle casting and stainless steel pin which is
attached to the keel. The pintle is set in a polysulfide bedding
compound and fastened onto the hull with bronze rods that pass through
www.capedory.org - 22 -
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