Sanding … sanding … and when you think you have done enough SAND SOME MORE!

The plug for the SageSport 160 is now nice and shiny and we have begun the process of making the mold!

Shinny plug that is ready for gel coat!

Spraying gel coat – this will be the surface of the mold.

Here the first of many layers of fiberglass are layed over the gel coat – 

Balsa is added create a strong and stable mold. NOTE: the hull of the SageSport 160 WILL NOT be cored with balsa!!!!  This photo is of the hull mold NOT a boat.

And more glass is put over the balsa –

Here is a link to more pictures of the hull mold being made: –>CLICK HERE<–

Next the second half of the mold will be made and then the first fiberglass, Kevlar and carbon fiber SageSport 160 hull will be made!

Progress on the SageSport 160’s hull mold

The first step is to make a plug from which the SageSport 160 mold will be made. These pictures show the hull being made in cedar strips over the form stations –

 

The last slat goes into the hull. This is called the ‘whiskey plank’ –

The hull shape is complete. Here you can see the plug and the prototype boats –

Once the strips were in place the boat was sanded smooth in preparation for a layer of fiberglass to cover and stabilize the shape –