More Carbon Fiber Fun!!!!

When I started this project, it was intimidating for sure. I am working on my bosses boat, the loads these parts will see could exceed 1,000 lbs and I am drilling into a one of a kind carbon mast that can't easily be replaced. If that was not enough, I am making parts that only exist in John's and my minds. As things have progressed my confidence grew and the creative juices started to flow.

Russel Browns Proa, Jezzero

Jezzero at speed

So what is a Proa? The design originates from an outrigger canoe. There is a main hull, which by itself is not capable of remaining upright. So, a smaller outrigger hull is added for stability. Both hulls are narrow in profile, much like a knife in the water. So when propelled with a sail, what you get is an extremely efficient, smooth sailing craft. So far Madness has achieved 15 knots without breaking a sweat. The rig that propels Madness is a somewhat high tech rig. What makes it different than traditional sailboat rigs, It has two jibs and the mast rotates 180 degrees. So this is where all the upgrades come in. Since the rig rotates, none of the control lines can transfer from the mast to the deck. Halyard clutches, a winch base, sheaves and rope outlets had to be created from scratch.

The clutch base ready for  a couple layers of Carbon Fiber

The first of two layers of Carbon fiber

The finished rope clutch mounting base

A side view of the clutch base, ready to be installed

Installed and ready for action

The beginning steps of the winch base, there are 6 nuts bonded to the bottom

The base bonded to the collar with the carbon reinforced "Kitty Hair"

The base formed with more carbon reinforced kitty hair. This stuff was hell to sand!

The cutting jig for a uniform cut on a curved shape. The band saw made quick work of this

The winch base ready for more carbon fiber 

The first of two layers of Carbon fiber cloth

A couple coats of epoxy, bring out the pattern of the cloth

The finished base with the winch installed

The Spinnaker Halyard exit plate 

The beginning of the Spinnaker Halyard Sheave

Add carbon fiber and epoxy.....

The Sheave plate just before installation

  I have one more week to finish this up. The most challenging carbon wrap job is coming up on Monday. I have to add one more sheave at the bottom of the mast and then it is time for paint. A nice satin black paint job, clear on the carbon fiber parts and it's off for testing. Fingers crossed that it all works. The boat has a trip planed with a fellow builder and author, who is writing an article for WoodenBoat Magazine. No pressure!