2016.05.13 - Shoddy Work
The method used to put in the first rib was a mistake and the result looks shoddy. It is going to take a lot of work with sandpaper and chisel it a cramped position to make it look reasonable even though most of it will not be seen as it will be covered by a bunk and a locker. Nevertheless, it has to be made smooth so that skinned knuckles are not the result of rummaging through a locker or under the bunk and slicing flesh on the sharp pieces of epoxy.
This is one of the drawbacks of using epoxy. Once the epoxy is cured changes require a lot of brute force possibly including destruction of the offending part and replacement with the correctly done piece. In this case the situation is salvable, the rib is not structural after all, but I’m not going to enjoy doing it.
I decided to leave that for the moment and put in the other ribs but making a template for each one, then constructing a bending jig and finally gluing the laminates around the jig. You can see the second rib for the starboard side being made this way below. Surprisingly it worked well apart from the short bit at the inboard end. Well, surprisingly for me, that is. As you can see below the rib is a very good fit and it fits well enough on the other side that I can use the same jig for the opposing rib and that is currently in the jig waiting for the epoxy to cure.
The already cured rib isn’t finished yet, I have to put it through the planer to remove the epoxy that squeezed out of the sides but even in this state it looks better than the first rib.
Here the laminates for the second rib on the starboard side are in the bending jig and waiting for the epoxy to cure.
Twelve hours later the clamps are removed. Notice that there is no spring back, the rib still lies pretty snugly against the jig even though the clamps are gone.
The rib placed in the position it will be fixed to check for fit. The sides have yet to be planed to remove the excess epoxy but it looks quite good.