Perfecting the stern mold turned out to be the most critical and time-consuming part of this project so far. Rationally, you know you have to get this part right because everything depends on the quality of this effort ~ from looks to strength to finishing work required.
The mold is what bridges the design with project execution. Even the best designs need an even better plan to get to a good result. Despite being told so, when it felt like an endless cycle of measuring, fitting, filling and fairing the insides smooth, I now appreciate that making the mold is the biggest proportion of this work.
Oh, and since this is my first time seeing a mold being built, I lovingly referred to ours as Frankenmold. No offense to the workmanship whatsoever, since we all know it's what is on the inside that counts!
Coming together from various pieces of fiberglass and plywood, the mold pieces are aligned precisely and then held in place with screws.
The pointy end of these screws are not conducive to laying fiberglass, so they must be chopped off and then filled (resin putty) and faired (sanded) so that no bumps or holes remain.
Likewise, with each seam that comes together you must get rid of any lines or edges that remain inside the mold.
Getting the smoothest surface and desired radius for curves and stairs took days and days of sanding and perfecting shapes.
The result is a female mold of the exact template that will shape the outside of the new stern.
The mold was built-to-fit right on the original stern, such that it encapsulated the entire 3D [internal] surfaces to perfection.
Since none present knew how to lay fiberglass in 3D (joke), the mold was then cut in half for ease of final layup.
An important lesson during this entire stage (besides patience) was being able to change your mind or make a decision that may take you back a few steps. As things evolve, each new decision has a consequence to the final build ~ for good, bad or indifferent.
For example, Mark envisioned originally that two side-hulls, steps and stern would each be made separately and assembled later.
The decision to make a monocoque mold alleviated the need for mini-bulkheads in the two side-hulls, one shown here, where now a single bulkhead will be installed running down the steps.
It has been interesting to watch the design to execution stages take place.
These guys rely on each others' expertise in certain areas.
Noé has a quick mind, a good eye and years of hands-on expertise. Mark also comes with lots of knowledge and fiberglass experience. Saul executes most of the work and is a wiz with fiberglass. Dony is the overall helper and no detail escapes his attention.
Mold complete, on goes the wax and first layer of gelcoat to prepare for the layup of the stern. Excited!!
