In the last post for the Sugar Scoop construction, we saw how the parts are outlined with masking tape on a waxed mirror or window glass.
Some parts outlined in masking tape on waxed glass.
This process ensures a smooth defect free outside surface as the outside is laid against the waxed glass and the layers of fibreglass are laminated on top in a outside to inside approach. Another method is to make just sheets of white gelcoat fibreglass panels then cut out the parts, but this wastes material. Outlining the part with masking tape allows one to easily apply the gelcoat and fibreglass only where it is needed. In either case the final parts need be trimmed to size, but less waste is generated by masking a part outline. The orange part is the mold for creating the boarding ladder recess in the transom step.
White Gelcoat applied to exterior areas of swim step.
White gelcoat is painted onto the exterior surface areas only. The transom step is made in a two pieces and joined together (the sheet of glass was not large enough to laminate in one piece). The seam will be at the center of the step where there is an internal support.
Detail of ladder recess mold.
Remember, this view is upside down from inside the swim step. The orange mold will be released, revealing the finished white recess where the swim ladder will be mounted. The ladder telescopes and folds into the recess area. You will get a better idea how this works when you see the finished sugar scoop.
White gelcoat outlines ready for fibreglass layup.
Four pieces are laid out on this sheet of glass. The two outlines, half white, half clear, will be joined to make the horizontal swim step surface. The clear areas will be inside the cabinets and are not finished white until all the glass lamination is complete inside the cabinets. For now, the areas to receive further lamination or tabbing are left without white gelcoat for a better fabrication bond. When the gelcoat is cured, fibreglass layers can be applied.
Finished lamination ready for cutting
A pair of small panels with a single 1708 lamination, along with 6 oz cloth and surface veil is removed from the mirror surface and ready to be trimmed to final size. The thin panels will be easier to bend for assembly. The parts will be tabbed together from the inside and then more fibreglass layers applied from the inside of the cabinets.