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Old 10-10-2012, 07:02 AM   #1
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Default 41 express triple outboard build thread (renamed)

Had a visit from esteemed THT'ers Bly and Capt Hugh Wild yesterday in my shop and they urged me to post up some pics of a 37' express we are building. Bly particularly was suprised to see custom Carolina styling combined with modern composite construction methods.

Hull Specs;
37' LOA
13' 6" beam
16 degree transom deadrise
fuel 540 gal
water 125 gal
power twin 500 hp diesels
Conventional inboard shaft drive with Twin Disc joystick control system

The hull is cold-molded and started upside down on a jig with the laminated stringers, keel, chine and knuckle installed for the planking to attach to.
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Old 10-10-2012, 07:07 AM   #2
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Then the planking is added, two layers of 1/2" AB marine fir ply on bottom and two layers of 1/4" Okoume on the sides. The reverse chine is added as well as the high density foam (Coosa) bumbers and corner guards. Then the entire hull is sheathed in a layer of Kevlar hybrid with a layer of eglass on top.
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Old 10-10-2012, 07:12 AM   #3
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Default Now the fun starts!

Once everything is glassed we start the fairing process. High-build primers, fairing compounds hand sanded with 7' and 4' long boards. Several passes are made spraying fairing compounds then sanding, 80 grit, 120 grit then 220 grit, much easier to do upside down!
Reverse chines are also put on while upside down, high density foam.
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Old 10-10-2012, 08:17 AM   #4
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Default Fliping the hull upright

Once the hull's faired to 220 grit we called the crane to flip her over. Some guys do it with tires on the ground but always seem to tear up the sheer clamp. We use two sets of cables and she never touches the ground.
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Old 10-10-2012, 08:34 AM   #5
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Seems to be coming along great, looking forward to seeing more pics!
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Old 10-10-2012, 09:20 AM   #6
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Default Starting on the inside of the hull

Once flipped we pulled out all the jig frames and installed the bulkheads which are made out of Divinycell foam core and glassed-in. Then we vacuum bag the same foam into the hull sides. We use vacuum bagging to get the foam to bend into the hull shape rather than screws and battens. The perforated foam allows air to escape and when the thickened epoxy oozes out you know it's pulled down tight and don't have any of the dreaded core voids. The bulkheads are fit to the outer hull skin and when we add the core it helps lock them in better. We then add an inside layer of plywood and glass to complete the sandwich. Compared to a "traditional" cold-molded hull, the addition of a closed cell foam core adds strength, sound and heat insulation with very little weight penalty.

Also some pics of the rudder table being installed and the strut blocking. It is also keyed in to the transom before the core is added.
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Old 10-10-2012, 09:31 AM   #7
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very cool build. i may get blasted for not knowing this but whats the name of your company?
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Old 10-10-2012, 10:30 AM   #8
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Lightening Yachts
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Old 10-10-2012, 11:28 AM   #9
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Lightening Yachts
thanks.
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Old 10-10-2012, 12:35 PM   #10
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Default Nice Job

Hi Bill,
Very nice indeed !!
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Old 10-10-2012, 12:40 PM   #11
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I think I'm going to be in love. . .keep the pics coming.


I'm not familiar with the "twin disk joystick controls", my first thought was pod drives but you mention straight inbords, is it twin disk transmissions? What are the joysticks for?
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Old 10-10-2012, 12:47 PM   #12
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Default After the hull is skinned inside

We then glassed everything from the sheer clamp down. Fuel tanks went in next while the cockpit honeycomb deck was made. The dark area in the middle of the deck is the fighting chair backing, Coosa board sandwiching a 1/2" aluminum plate. Lazzarette was faired and topcoated and 8" liner mufflers installed prior to the deck being epoxied in place. Shot of transom is the forward end of the fish box being vacuum bagged to shape using the transom as a "mold". 1-1/2" thick Divinycell foam glassed on both sides.
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Old 10-10-2012, 12:59 PM   #13
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That hull has some of the prettiest lines Ive seen! I like the idea of using the transom as a mold during the vacuum bagging of the fish box, pretty clever. More build pics please.....!!!!!
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Old 10-10-2012, 12:59 PM   #14
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Default building up the cockpit and bridge deck

Friring out the engine room, you can see the integral water tank on the forward bulkhead that will also be an equipment shelf. All the decks are on, fordeck is 3/4" Nida-Core honeycomb, bridge deck 2" and cockpit 1-1/2". Brow is 2 layers of DIvinycell laminated in place and sides are 1-1/2". COvering boards and fishbox are now in, she's slated to get teak covering and coaming but we glass everything under just in case!

Because she's so low profile we decided to draw engine air on the cabin sides and duct it down under the side covering boards. There will be a plenum inside the seating that redirects to those 6" tubes in the last shot that dump fresh air evenly down the side of the E.R.
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Old 10-10-2012, 01:00 PM   #15
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Default twin disc ejs

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Originally Posted by Ryan H. View Post
I think I'm going to be in love. . .keep the pics coming.


I'm not familiar with the "twin disk joystick controls", my first thought was pod drives but you mention straight inbords, is it twin disk transmissions? What are the joysticks for?
http://www.twindisc.com/MarineProducts/EJS.html
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Old 10-10-2012, 01:09 PM   #16
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WOW! I love these builds
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Old 10-10-2012, 01:13 PM   #17
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Quote:
Originally Posted by Ryan H. View Post
I think I'm going to be in love. . .keep the pics coming.


I'm not familiar with the "twin disk joystick controls", my first thought was pod drives but you mention straight inbords, is it twin disk transmissions? What are the joysticks for?
Twin Disc has a joystick system (EJS) that gives the same manuverability features as the pod drives with a joystick control, turning, spinning on axis, sideways etc. but they can do it with conventional drives, twin inboards and a bow thruster or even a single inboard with bow and stern thrusters! You also have a set of single lever controls for normal cruising but when docking you can switch to the joystick and drive like a pod boat would. Amazingly enough the system does NOT manipulate the rudders, it just uses the engines and thruster (s). ZF has a similar system (JMS). I personally think it's an excellent idea as it can allow existing big boats to be retrofitted with pod-like control systems without major modifications to the hull structure or waiting years for larger pods to be released that can handle the bigger engines these boats have,
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Old 10-10-2012, 01:20 PM   #18
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Twin Disc has a joystick system (EJS) that gives the same manuverability features as the pod drives with a joystick control, turning, spinning on axis, sideways etc. but they can do it with conventional drives, twin inboards and a bow thruster or even a single inboard with bow and stern thrusters! You also have a set of single lever controls for normal cruising but when docking you can switch to the joystick and drive like a pod boat would. Amazingly enough the system does NOT manipulate the rudders, it just uses the engines and thruster (s). ZF has a similar system (JMS). I personally think it's an excellent idea as it can allow existing big boats to be retrofitted with pod-like control systems without major modifications to the hull structure or waiting years for larger pods to be released that can handle the bigger engines these boats have,
Hi Bill,
The single inboard EJS sysytem is not yet released isnt it?
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Old 10-10-2012, 02:13 PM   #19
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Hi Bill,
The single inboard EJS sysytem is not yet released isnt it?
Greetings Doc,
I'm not sure about the released part yet but the test boat is sitting in the water about 1/4 of a mile from my shop and has been running for several months now doing demo and test rides. I'm sure a test run could be arranged anytime! As you know, the hardware used in the system is off the shelf; MGX transmissions, thrusters and hydraulic valve assembly, so if there's any holdup in production release components it will be the control boxes or software.
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Old 10-10-2012, 02:36 PM   #20
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Thanks for the info Bill....I bet it will cost a fortune for that EJS
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