Hull #1216

Restoring your Falcon? Come in for tips, and share your knowledge.

Hull #1216

Postby ngurney » Sat Sep 03, 2011 6:10 pm

HI-
Recently acquired Falcon hull # 1216, and I am restoring it this winter. If anyone has any production drawings (blueprints), especially pertaining to the centerboard apparautus, I would greatly appreciate it. Thanks.

Nick
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Tue Mar 20, 2012 10:10 pm

Here are some before pics, and some showing the dismantled product. Some of the gear, like the main sheet/boom vang, the traveller blocks stays, and the mast stays will stay because I can't easily get access to the nuts on the underside of the deck. They are in good condition though, and should be good for a long time yet. Anyone have any good ideas for a rig to flip this thing over? I guess six men and some beer would work........I plan on replacing the brown house paint, (and all other paint) with new gel coat.
Lots of home made modifications here....rudder brackets are plain steel, plastic tiller lock, painted plywood cuddy hatch cover.jpg
Lots of repairs here....rudder gudgeons are plain steel, the plastic tiller bracket is a good idea for holding the tiller while sailing single handed, the plywood cuddy hatch needs to be replaced, etc. etc.
Attachments
Somebody hacked into the CB trunk at some time.jpg
Somebody hacked into the centreboard trunk at one time
Here's a repair done by the previous owner, after a collision with the trailer. This is the starboard bow area.JPG
Here's a repair done by the previous owner sfter a collision with the trailer
Last edited by ngurney on Wed Mar 28, 2012 7:56 pm, edited 2 times in total.
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Tue Mar 20, 2012 10:17 pm

Original McVay logo...I'm going to have new copies made.JPG
Original McVay logo......I'm going to have new ones made
Getting ready to build a cradle.JPG
Getting ready to build a cradle
Coamings and hardware removed.JPG
Coamings and hardware removed
Hull #1216
More pics
Last edited by ngurney on Wed Mar 28, 2012 7:34 pm, edited 1 time in total.
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Tue Mar 20, 2012 10:22 pm

Hull #1216
More pics
This has been jerry rigged, and not very well.JPG
This has been badly jerry rigged
Came off with out too much fight.JPG
Came off without too much fight
100_1344.JPG
All cleaned up
Last edited by ngurney on Wed Mar 28, 2012 7:48 pm, edited 1 time in total.
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby DaveD » Tue Mar 20, 2012 10:23 pm

I still haven't finished my bottom yet.

I planned on lifting the trailer tongue until the skeg is touching the ground, then having a couple people hold up the bow while I pull the trailer out from under. Then lower it down till its laying on the ground flat.

Roll it over onto some blocks that are higher off the ground than the cuddy is high. The deck and stern should be supporting the weight. The cuddy isn't strong enough to support all the weight.

Good luck!
A bad day sailing is better than a good day at work...
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Re: Hull #1216

Postby DaveD » Tue Mar 20, 2012 10:27 pm

Oh, and the keel locker components and setup didn't change in the 20 some years of production.

In addition, it's very similar to early DS rigs. you maybe able to get some parts from DR Marine posted under the suppliers section. I got gaskets for mine there.
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Re: Hull #1216

Postby ngurney » Tue Mar 20, 2012 10:28 pm

That's a great idea, Dave. Very simple, and pain free. I had all kinds of Rube Goldberg schemes in my head....thanks for saving me the agony.
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Re: Hull #1216

Postby ngurney » Tue Mar 20, 2012 10:31 pm

Thanks...I'll have a look at the DR site.
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Re: Hull #1216

Postby DaveD » Tue Mar 20, 2012 10:33 pm

That should cut the help down to a couple of friends, and keep more beer for yourself. :D
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Re: Hull #1216

Postby ngurney » Tue Mar 20, 2012 10:36 pm

I like the way you think, Dave.......

More pics


CB, showing a piece of aluminum angle somebody screwed onto the leading edge....can't imagine why.JPG
Centreboard, showing a piece of aluminum angle screwed onto the leading edge....what for?
CB not in bad shape overall....I'll need to reform the square receiving hole.JPG
CB not in bad shape.....receiving hole needs to be reformed
Not much to it really....square peg in a square hole.JPG
Square peg in a square hole
Last edited by ngurney on Wed Mar 28, 2012 7:52 pm, edited 1 time in total.
Work is the curse of the drinking classes.
ngurney
 
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Re: Hull #1216

Postby ngurney » Tue Mar 20, 2012 11:32 pm

Dave, I saw the proper gear for sale for my CB, on the DR Marine sight.......only glitch is the $215.00 price tag, plus shipping. I'm pretty sure I can make most of my parts work, and only have to fabricate one completely new part. I should save enough for, let's see.....about seven cases of beer.
Here's another question.....I see that everybody is using epoxy resin for repair work........somebody who should know told me that 99.9% of commercial FRP boats are made with polyester resin, not epoxy, especially if they are older, because the cost is only about 40%-50% (or less) of epoxy.......I have bought polyester resin for my repairs.....I hope I won't have any issues.......any thoughts?
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby DaveD » Wed Mar 21, 2012 12:10 am

You might try giving the guy a call at DR and talk to them. Explain you beer situation. :-)

I chose epoxy resin because it seemed easy to work with, and I could use it with a variety of fillers and in different applications. I also chose West System, because it comes from my hometown in Bay City, Michigan and support was really easy if I had questions. (I worked a couple blocks from the shop). My understanding is the support is just as good if you pick up the phone.

I'm sure all of the other epoxies have their benefits etc, but I only know what worked for me.

Polyester will work, but:

1. You will need to seal the surfaces thoroughly for it to cure properly, and if you plan on keeping your boat in the water all season, polyester can cause osmosis and delamination if not sealed properly.

2. Epoxy is a better adhesive, and it seals also (I coated my stringers and other woodwork to prevent rot). Polyester crystallizes and can cause bonding issues.

Also, epoxy will bond like crazy to polyester, but the reverse is not true. If you plan on re-gel coating, this might be of concern. I used Brightside right over my repairs, no issues.

In addition, epoxy generally is stronger than the poly, so you may use less material to accomplish the same strength results. Epoxy can have fillers added to increase strength or flexibility if needed. The carbon fiber hulled boats are laid in epoxy. :D
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Re: Hull #1216

Postby ngurney » Wed Mar 28, 2012 7:13 pm

The price of epoxy in my neck of the woods is criminal......around 170.00 a gallon, so for this project, where there is very little structural work required, and budget issues, I have to go with polyester. Also, I bought a gallon of gel coat of a mismatched colour from the local supplier for 30.00, so the polyester resin is pretty well a requirement for that. Wait 'till you see the colour!.........it's on the centreboard in the picture.
100_1345.JPG
New home made thingy for the CB retainer........doesn't look like it, but it is stainless
100_1351.JPG
Rebar reinforcement for the cuddy roof....it was very weak
100_1354.JPG
New thingy glassed into place
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Wed Mar 28, 2012 7:20 pm

More pics
100_1361.JPG
Rebar reinforcing with two rough coats of resin.....needs a good sanding to shape it, and then some cloth and fairing
100_1357.JPG
CB with a trial coat of the new gel coat colour.....not far off your boat colour, Dave
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby DaveD » Thu Mar 29, 2012 12:33 am

Scientifically proven: Yellow makes your boat faster.

:)

Looks good. I especially like the custom stainless "thingy". Too bad the original corroded out like that.

I hear you on the prices. Gelcoat and poly are going to be just fine. Just make sure you seal it up right.

I like how this is going... :mrgreen:
A bad day sailing is better than a good day at work...
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Re: Hull #1216

Postby joecomet » Fri Apr 06, 2012 9:30 am

I think the leading edge metal piece on the centerboard, is for sailing around a lot of oyster bars, (I don't mean the kind where you get your beer), like up here in the Florida Panhandle. Eat'um is one thing. Chewing out your underwater parts is another.
Joseph
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 8:17 pm

100_2069.JPG
A boat of many colours
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 8:22 pm

(Sorry about the size of the pictures,....cant figure out how to make them smaller)

Finally got back on track with the project ....you know how it is with this stuff.
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 8:35 pm

100_2084.JPG
Hole from collision
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 8:43 pm

100_2091.JPG
Hole repair
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 8:47 pm

100_2072.JPG
#1 helper, with work truck
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 8:52 pm

100_2086.JPG
Sanding mostly done
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 8:56 pm

100_2096.JPG
New colour scheme.......the nasty yellow I had bought cheap was just too hard to look at
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 9:07 pm

100_2417.JPG
Ready to go
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 9:13 pm

IMG_0297.JPG
I named the boat after the guy I bought it from.....crusty old fellow who had been a fishing captain on a big boat for 30 odd years. When he retired, he sailed this around his home port with his son....
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby ngurney » Fri Jul 18, 2014 9:17 pm

100_2433.JPG
Into the sunset
Work is the curse of the drinking classes.
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Re: Hull #1216

Postby DaveD » Fri Jul 18, 2014 9:45 pm

Nick,

Your work is absolutely stunning.

Congratulations on finishing and getting on the water. Many, many more years of sailing to come!

--Dave
A bad day sailing is better than a good day at work...
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Re: Hull #1216

Postby ngurney » Sat Jul 19, 2014 2:39 pm

Thank you for the compliment, Dave....and thanks for your work in looking after this forum. My son deserves a lot of the credit....its good to have help.
I see other Falcon owners from time to time on other boat forums. Hopefully they will find their way here at some point and put up some posts.
Cheers!

Nick
Work is the curse of the drinking classes.
ngurney
 
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Re: Hull #1216

Postby mainefalcon » Wed Jul 23, 2014 9:10 pm

Hi Nick,
Nice work--the end result is stunning!! We had a similar restoration project on our Falcon a few years ago, and it is definitely worth it. We were late getting started this summer--we just took our first sail this afternoon, and like every time we go out, we always say the work on the boat was worth it. I hope you enjoy your Falcon as much as we enjoy ours.
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