Building the Osprey Standard (Continued)
After the hull had cured overnight, I flipped the boat over and did the first coat on the deck. I used the small brush and did the cockpit combing first. I then started at one end and went from side to side until the entire deck was coated. I worked quickly but very carefully trying to make sure everything was just right.
This whole finishing stage can be maddening because it is so subjective. Several people came over and thought the boat was glorious. I found myself pointing out the thin spot here, the sag there, the dust particle there. My wife keeps telling me that this is a "boat", not a dining room table! It will soon be on the car, in the mud, hitting rocks… I am trying to find some middle ground but it is very difficult. When everything is right the surface is just awesome and it is hard (as the craftsman) to ignore the blemishes.
It is now June 7. I sanded the deck this morning in preparation for the next coat. I moved to 220 grit on the sander and was extremely cautious. I just went after major flaws (my wife couldn't see them) and then moved to 320 wet sanding. I then did the second coat. It seemed to go pretty well but after I was done it just sagged all over the place. I was trying to get good coverage but apparently put it on too thick. I thought I would keep getting better but this was the worst coat yet!
Well, they say that sanding can cure most anything and I was determined not to let this latest coat stop me. Since I had two coats on everything, I carefully sanded the entire boat in preparation for the third and (hopefully) final coat. With 220 in the sander I took care of the sags and runs and then wet sanded everything with 320. I washed it down, removed excess water with the squeegee, dried it with a towel and carefully removed any trapped dust with the toothbrush. I have decided that I am switching to foam brushes to see if they might be more forgiving.
You certainly see arguments both ways regarding bristle versus foam, but for me I find the foam much easier to work with. I did the hull first and I think that I was overly cautious. The coating may be a bit thin, but it looks fine. I am definitely using a foam brush for the deck.
Prior to applying the final coat to the deck, I marked the locations for the holes that will be drilled for the deck rigging fittings. I just felt safer doing the layout on the bare epoxy than on new varnish. Then I applied the final deck coat and I am quite pleased with the results. It is not a dining room table but it is a very respectable finish.
When the varnish had cured overnight, I drilled the holes for the deck rigging (Tip 18) fittings a bit oversize and applied a coat of epoxy to the exposed wood. When the epoxy had set up I installed all of the fittings and attached the rigging (Tip 19). The following day I tightened all of the fittings again since the wood under the screws had compressed somewhat.
So, she is finally complete on June 10 and here she is. The final weight on my digital scale is 35 pounds.
P.S. Also check out my tips on epoxy, horses and other Tips and Tricks.
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