Formula 330SS Bulkhead Replacement

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

I made a new label for the fuel tank, since the original one got trashed during the paint removal process.



I suppose that I should pressure test the tank once I have it all prepped and before I paint it. . . . the label will be set aside until the tank is ready to go back in the boat.

 

[GT1000000]

Re: Formula 330SS Bulkhead Replacement

Tank is looking great, hope it pressure tests OK...
Hey great looking label...how did you reproduce it?
BTW, that place is just up the road from me...Hialeah...definitely a drive thru town......

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Tank is looking great, hope it pressure tests OK...
Hey great looking label...how did you reproduce it?
BTW, that place is just up the road from me...Hialeah...definitely a drive thru town......

Fortunately I had a reasonable photo of the label. I needed to clean it up a bit, then printed it and used acrylic sealer to finish it off.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Here are the 'before' and 'after' images of the fuel tank label . . .

I inadvertently splashed some paint remover on the label, which immediately loosened the ink, etc. So, the label was a lost cause. This is the only photo that I seemed to have of the original label.



some blemishes and scratches to it . . .

So, I reworked and cleaned up the image using a variety of photo software on my computer and came up with this image. It still has a bit of 'keystone' to it, but it is OK.




Today, I plan on cutting into the sole of the storage compartment that is just forward of the front bulkhead of the fuel tank bay. The forward bulkhead has absorbed moisture in the center/lower section, so I am going to inspect the foam along the keel in that section for moisture, etc. I'd like to figure out where the moisture has been 'feeding' from. My thoughts are that it could have been coming from the wet foam in the fuel tank bay, or from wet foam in the sole of the storage compartment that is just forward of the fuel tank bay, . . . or a combination of the two.

 

[GT1000000]

Re: Formula 330SS Bulkhead Replacement

Thanks, Ted...That is a great idea for re-doing my tank label, and maybe a couple of others...
I sure hope you can find the source of the moisture...that would go a long way to being able to prevent any future issues...

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Update:

I cut into the sole of the storage bay, which is directly in front of the fuel tank bay . . .
The saw dust was dark, which told the story as I uncovered the structure beneath the decking



The foam and the surrounding structure was fairly wet


I also found the forward mini-bilge, which I was not fully aware of previously . . . sort of hidden underneath the carpet.


Here is the opening that I made, once it was all cleaned up . . .


I may cut open the outer areas tomorrow. Then I'll see about replacing the structure.

I guess I know where the moisture in the forward fuel bay bulkhead was coming from

 

[zool]

Re: Formula 330SS Bulkhead Replacement

Wow Ted, you're really starting to dig into it, already into spring, you plan to make the season?...looks like you may have a bigger project than planned...then again, maybe with some sistering, you can clean it up and get it glassed and going by summer....you're already in there, so nows the time to do what you plan

 

[alldodge]

Re: Formula 330SS Bulkhead Replacement

I also found the forward mini-bilge, which I was not fully aware of previously . . . sort of hidden underneath the carpet.

Looks like that attitude adjuster in the pic is telling some items need a bit more to come loose.

If your anchor locker isn't bringing in the water maybe the water lines. It is starting to warm up, your season may be getting shorter.

 

[jbcurt00]

Re: Formula 330SS Bulkhead Replacement

Bummer, how contained to you think the water intrusion is?

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Not sure how far the moisture goes towards the bow. If I replace the carpet in the main cabin at some point, then it would be a good time to check the cabin floor. I did open up more of the decking/sole of the storage compartment today.



I figured that the structure probably should come out, so I cut the sole around the perimeter and pried up the plywood. The outer chambers were somewhat wet.



The area is a bit tight to work with the sawzall, so I may have to give it some more thought as to how to cut out the ribs/cross members. I think I will let the area dry out for a week or two and check the moisture levels in the cabin bulkhead, which is where the carpeting starts.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Meanwhile, I picked up some aluminum cleaning supplies in town . . . found "Aluminum Jelly" that companion product to "Naval Jelly". So I did some more cleaning and prep work on the fuel tank.



Here is the Aluminum Jelly doing its thing.


After the tank was all cleaned up, I did a pressure test.


I used a hand pump and my leak tester gauge, just to be sure not to pressurize the tank too much.

Now just waiting for a couple of nice sunny days for priming & painting.

 

[bigdirty]

Re: Formula 330SS Bulkhead Replacement

meh, no prob, you will be in this season, thats nothing :lol: nice work on the fuel tank tag btw

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Looks like that attitude adjuster in the pic is telling some items need a bit more to come loose.

If your anchor locker isn't bringing in the water maybe the water lines. It is starting to warm up, your season may be getting shorter.

Bummer, how contained to you think the water intrusion is?

Yea, I'm not sure how the water has been getting in there, other than condensation and the the occasional use of the tube for water sports. I think the key thing is that the mini bilge beneath the carpet has probably never been checked and sponged out. The two 'mini bilges' have covers on them, which kind of makes them condensation traps.

Wow Ted, you're really starting to dig into it, already into spring, you plan to make the season?...looks like you may have a bigger project than planned...then again, maybe with some sistering, you can clean it up and get it glassed and going by summer....you're already in there, so nows the time to do what you plan

meh, no prob, you will be in this season, thats nothing :lol: nice work on the fuel tank tag btw

I will have to make a schedule and see how things look as far as getting the boat in on Memorial Day, which is my normal launching day. (not that I make that date on a regular basis, but I try) I have 4 company holidays coming up in April, so that is like getting 2 extra weekends.

My next steps are to complete the cut-out of the storage compartment sub-structure, then start making some templates for the new bulkhead and other pieces. Then it is off to Home Depot to get a piece of 3/4" exterior grade plywood.

I'll have to order a bunch of 'stuff' from US Composites . . . I was thinking about 3 gallons of VE Resin and a 16 cubic foot kit of 4 lb density foam. I have some CSM and 1708 lying around from my 242 bulkhead repair project of a few years ago. I'll have to get a good measure to see if I need any more Fiberglass fabric.

I think my biggest problem will be the weather . . . Cape Cod stays fairly cold throughout the Spring months due to the ocean waters. Last year, I remember struggling to get a 50 degree day during May

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

SCHEDULE UPDATE . . .

I did a bit of estimating and figured that I have a total of about 80 hours of work to go in order to finish ripping things out and put it all back together. I got 4 extra days off this months, so with weekends, there are 10 'boat working' days remaining in April.

I *should* be able to finish the repair work by the end of April. Then I will be onto my regular prep work in May. I have a few weekends of traveling in May, so launching may not be until early-mid June.

I'm checking my list of 'planned' improvements to the boat, and will probably delay most of them until after launching or even into next year. I do have to replace a drive shaft seal on the port outdrive . . . so that is my big 'regular' maintenance item for the Spring.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

OK, I just ordered some 'stuff' from US Composites . . .

3 Gallons of Vinyl Ester Resin

20 cubic foot kit of 4 lb/cu-ft of urethane foam

extra MEKP ( because the working temperatures will be on the low end)

I did not order any cloth at this point . . . gotta check my supplies to see if I have enough already.

Of course as I am ordering the materials, I am saying to myself . . . should ordered this stuff last week. I hope it gets here by Monday . . . I have Tuesday-Wednesday off and will probably be needing it by then.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Update on the Forward Bulkhead & Storage Compartment . . .

I managed to cut out the substructure of the storage compartment floor using my sawzall. Here is a picture of the wood ribs removed and the remains of the tabbing base.



Then it was on to the grinding.







I went to the local Home Depot this morning in search of exterior rated plywood, but all they seemed to have is "Exposure 1" rated Sheathing. So, I did not get any wood at that point, as I wanted to check out the difference between "Exterior" and "Exposure 1" ratings. It turns out that the Exposure 1 rated plywood uses the same glue as Exterior rated, but the wood and/or the lamination is not intended to stand up to long term exposure to moisture. So, I am best to get Exterior rated Plywood.

I also did some grinding on the rear bulkhead areas, but have some more to go . . . that will have to wait until tomorrow.

I have Tuesday and Wednesday off from work and my order from US Composites should arrive on Monday. So, hopefully, I can be tabbing in the new bulkhead and the ribs for the storage compartment this week.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

A little commentary about my plans for the stringer and bulkhead installation. The original factory installation uses a gap between stringer/bulkhead and hull as a means of reducing contact distortion in the mold. I believe it also provides a bit of energy absorption between the hull and the structural member.

The only problem that I see is that the underside of the stringer/bulkhead is exposed to water absorption, should any water penetrate the tabbing. So, my plan is to use a bit of CSM on the under edge of the structural components to provide better encapsulation. I also plan on going over the top of the stringers/ribs in the storage compartment with glass, as pictured below.

 

[alldodge]

Re: Formula 330SS Bulkhead Replacement

Doing a great job :thumb:
No expert here but have always heard that exterior grade is the same as marine plywood, but marine plywood has been kelm dried.

 

[bvetter]

Re: Formula 330SS Bulkhead Replacement

A little commentary about my plans for the stringer and bulkhead installation. The original factory installation uses a gap between stringer/bulkhead and hull as a means of reducing contact distortion in the mold. I believe it also provides a bit of energy absorption between the hull and the structural member.

The only problem that I see is that the underside of the stringer/bulkhead is exposed to water absorption, should any water penetrate the tabbing. So, my plan is to use a bit of CSM on the under edge of the structural components to provide better encapsulation. I also plan on going over the top of the stringers/ribs in the storage compartment with glass, as pictured below.

You're in the thick of it now!

I did the same thing, wrapped the bottom of the stringers with CSM. It's a bit of a pain in the butt, and adds an extra step, but like you said its an extra layer of defence against that pesky water.

Lookin' good!

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Doing a great job :thumb:
No expert here but have always heard that exterior grade is the same as marine plywood, but marine plywood has been kelm dried.

Thanks, guys for your kind words and encouragement :thumb:

You can Google plywood grades and find some information on the various grades. The major difference between Exterior and Marine grade plywood is in the quality & type of the wood. From what I have been able to research, 'Exposure1', 'Exterior' and 'Marine' grades all use the same type of glue, but the exterior and the marine grades are designed for longer term exposure to water/weather.

In terms of kiln drying, there is what is known as 'kiln dried after treatment' (KDAT), which is a process to dry out the 'wetness' of PT wood/plywood. Many/most boat manufacturers who still use wood in their construction have switched to PT plywood that is also kiln dried (KDAT), so that it can be immediately used in fiberglass layup construction. Common product names of PT/KDAT plywood are "Greenwood XL" and "Perma Panel".

Formula Boats now uses Perma Panel in their SunSport and PC lines. I believe that they have been using the KDAT stuff for about the past 12 years or so. Unfortunately, not back when my 330SS was made. . . IIRC, Chaparral and Grady White boats use the Greenwood brand of wood.

It seems that the PT/KDAT types of plywood are not generally available at a retail level.