NEW FIBERGLASS DECKS have been fitted to the two boats donated to the class last winter. [See Trapeze 134] Paul Hemker successfully created a mold off the deck of his Lindsay at his shop in Ohio.  The new decks constructed off the mold has now turned two older, formerly wood decked boat into hulls that will require little ongoing work.  While wood decks are very impressive to look at, we all know they require a great deal of upkeep.  The new fiberglass deck is not only cheaper than a wooden replacement deck, but it will last indefinitely, ensuring the new owner more time on the water and less time in boat maintenance.
 

The Bianchi+Checci FD US-1408, before redecking and restoration

Paul’s new decks are primarily fiberglass with foam core reinforcing at key stress areas.  These points are under the sides where the crew and skipper sit, and also under the foredeck. In addition to a half inch of foam core, the foredeck has two cross pieces also made of sandwiched foam core to support the deck.  This results in a deck that can be walked on, also an improvement over the wood deck.

The trick to this project was to create a mold that would allow for a wide variety of wood decked boats to be rebuilt.. Because these are expected to be older single, double or 1-½ bottom boats, Paul provided for extensions of the tabs than extend from the cockpit combing down 4 to 10 inches, depending upon the design.  During the fitting process, these tabs are cut out to follow the contour of the floor arrangement of the boat.  In the case of these first two boats, both were 1 ½ hulls, the tabs extend down 8 inches to the single bottom floor in the rear, and down only to the double bottom floor in the front half.  The tabs extending to the deck are attached to the floor with fiberglass tape.  The deck is attached to the hull with a polyester based adhesive.  The result is a snug, durable fit to the hull and floor

Accommodations for major hardware such as the genoa turning blocks and cleats points are built into the deck.  Because every boat is slightly different, the actual cutouts for genoa blocks and sheets, spinnaker sheets, upper and lower shrouds, and so on, are left up to the individual fitting. After some careful measuring, plus a saber saw with a fine blade and a drill, all required holes can be cut in about two hours.  Most of the key hardware fitting locations have been anticipated in the design, and the foam core is tapered down to the basic fiberglass.  When cutting out the upper shroud or twing holes, for example, a minimal amount of core is exposed.  Any foam that is exposed can be sealed off with silicon or epoxy.
 
 

The1978 Mader FD US-1406 with its gleaming new deck

The two boats are now being re-rigged. We’ve all probably noticed how boats tend to collect a lot of additional hardware over the years (weight and complexity being the issues here), and these boats are not an exception.  So as the rigging goes on, we have been focusing on keeping simple setups with a minimal amount of hardware and lines.  In the case of these two 1978 boats, most of the hardware and even some of the lines and wire could be reused. We are getting some donations of large spinnakers and these are being worked into the rigging.

When complete, the boats will be fully rigged and ready to race. Both have trailers and will sell for approximately $3000.  These will make great introductory boats for someone who is just learning about Flying Dutchman sailing.  For a relatively small investment, they will provide a complete FD experience, and will even be competitive in local and regional regattas.  They will be available for sale in late August or September.  Let us know if you know someone who is interested!

Next issue: The completed project!