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  #871  
Old 11-05-2013
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Re: Low buck projects- Let's see 'em!

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Replaced my companionway boards today. Lowes carries a plastic board now that is 11 inches wide and only 5/8 inch thick so it fit really well. The board was $30. The downside is they are a little heavy, but I plan to put some spare smoked acrylic in the middle one and a vent on the top one so that should help. The bottom one probably won't come out much.
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Any pics of how they overlap to keep water out?

Looks great.
I just beveled a 22.5 degree angle on the bottom and top. I did it with a table saw so they all fit together really tight. I thought about doing like a notch thing which would have worked find but seemed like overkill at this point.
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  #872  
Old 11-05-2013
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Re: Low buck projects- Let's see 'em!

I was making my coffee a few mornings ago and I heard a diesel engine approaching, then a huge blue mass slide by the port window over my galley. Of course, coffee comes first, so I made a cup and then poked my head topsides to see what had just come past. It was a bristol Swan 100 and she dropped the hook next to me.

This got me thinking that I had replaced these lexan windows in 2008 and how nice it was to be able to see through them! I researched a bit on sailnet and the other boards and found people polishing lexan with great results. I grabbed some 3M stainless polish from below the sink and went to town. Only a small amount of elbow grease and a few minutes of my time and the windows were like-new. For some reason, polishing plastic had scared me a bit but I could not be more impressed with the results:



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  #873  
Old 11-06-2013
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Re: Low buck projects- Let's see 'em!

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Using Brent Swain's idea I built a block...Instead of alluminum at $1 a pound I went for stainless at $1.80 a pound so $5.40 and the new cutting boards are only 1/4 inch thick so I bought 1 inch high density plastic...$10.00 only used 1/4 so $2.50 and stainless bolts $3.85...So all in at $11.75...
Bob142,

That is fantastic! Can you give some more detail as to how you made that?

Cutting and drilling the plate seems straightforward, but how did you make that roundover becket or strap at the top? Is there a way to do that without welding?

On the other side of the block, are the bolts that hold the sheaves in place just secured with a nylock nut?

If you tighten it too much, does that pinch the sheave or is there some sort of metal compression sleave around the bolt inside the sheave?

That is an amazing thing to be able to make yourself - I would really appreciate any insight as to how you did it.
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  #874  
Old 11-06-2013
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Re: Low buck projects- Let's see 'em!

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Originally Posted by Reefpoints View Post
Bob142,

That is fantastic! Can you give some more detail as to how you made that?

Cutting and drilling the plate seems straightforward, but how did you make that roundover becket or strap at the top? Is there a way to do that without welding?

On the other side of the block, are the bolts that hold the sheaves in place just secured with a nylock nut?

If you tighten it too much, does that pinch the sheave or is there some sort of metal compression sleave around the bolt inside the sheave?

That is an amazing thing to be able to make yourself - I would really appreciate any insight as to how you did it.
Not sure how Bob did it, but if I were to make one of those I'd insert a tube sleeve slightly longer than the sheave thickness, drill the sheave for the OD and run the bolt inside the tube. If the hole in the cheekplate is bolt size, the tube sleeve will prevent the 'pinching' of the sheave when you tighten the bolts.
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  #875  
Old 11-06-2013
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Re: Low buck projects- Let's see 'em!

Isn't that what the "breadboard" comments were about?
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  #876  
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Re: Low buck projects- Let's see 'em!

The roundover becket or stap was easy... it is a one piece unit...More wastage of material but stronger and as you bend it the edges naturally curl up...

Nylocks on the other side not as pretty as say pins with a circlip but cheaper and they don't tend to back off ...they aren't tightened down to pinch the pulley...

There is a piece of stainless pipe cut to lenght at the top and bottom bolts for spacers and the material is stiff enough that it doesn't bind...
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  #877  
Old 11-07-2013
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Re: Low buck projects- Let's see 'em!

Two questions -

What did the "breadboard" comments refer to?

Does anyone have any ides what it would cost to have the main body of a block like that cut by a waterjet.
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  #878  
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Re: Low buck projects- Let's see 'em!

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Originally Posted by SloopJonB View Post
Two questions -

What did the "breadboard" comments refer to?

Does anyone have any ides what it would cost to have the main body of a block like that cut by a waterjet.
Jon.. I think that referred to the idea of using a regular white 'cutting board' as source material for the sheaves... in the end he didn't because it wasn't thick enough...
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  #879  
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Re: Low buck projects- Let's see 'em!

Aaahhh - I thought it was for spacer blocks.

I think I'd spend the $2 for real sheaves - cheaper than a lathe.
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  #880  
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Re: Low buck projects- Let's see 'em!

Yes Brent used thick cutting board ...cut out with a hole saw.. put on a drill and groved with a rat tail file ...no lathe required...
I had access to a plasma cutter for the body but with extra time and effort a zip cutter and a grinding wheel will work...
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