Bayview Edison completed the hull plug yesterday. From what it looks like, they made just what we wanted, when they said they would (Within 2 days) and at the quoted price. I’m just tickled all over!

I just hope what we told them to make is what we really needed. Any case, here’s the story of the hull plug being built by Bayview.

After the 3D model is checked and agreed upon, Bayview gets busy and builds a wooden core for the part.

Leif & MikeS inspecting the wood core.

Once the wood core is built, a soft foam is sprayed over it. This is then machined down to get the rough shape of the part.

It was cool watching the shape of the hull emerge.

After the initial machining, a layer of fiberglass mat is laid down on the part. The fiberglass gives a stable foundation for the final shape. At least this is what I was led to believe. Makes sense..

After the fiberglass shell, an outer coat of thickened putty is sprayed on. This outer coat is what is machined to the final shape.

Getting close to finished with the machining step.

Next will be hand sanding and Duratac.

The finished hull plug. Now we’ll take it back to our shop, sand it smooth, add a trim flange and use it for making our hull molds.

Well, at least thats the plan..

Pulling it out of the milling machine..

Onto the waiting truck. We rented the truck and driver from a local shop here in town. That worked out great. The only way to move this kinda’ stuff..

Back at our shop dropping off the plug. We borrowed a forklift and cart from Jim Betts to help with this. There was no way we could have done it otherwise.

Thanks Mr Betts!

Sometimes its really handy having a bigger boat builder as a neighbor.

And here it is, home.

Its like having a baby grey whale taking up about 1/3 of our shop space.

Anyway, back to work.