The boat is unique. I have therefore developed a unique building method. To get strenght, boyancy and insulation for the southern winter combined with as low weight as possible I have chosen a sandwich core of 40 mm ( nearly 2 inch ) Divinycell foam of 100 kilo per cubic meter density. For a non-stop sail of one year the boat has no other choice than to be heavy. A heavy boat with a lenght of ten feet or three meter must have very compund curves with small radiuses. There is no other choice. It is impossible to bend that kind of Divinycell into that shape. I did not even consider it. Instead I chose the bricklaying method, building the boat of small bricks or tiles or quadrangels of Divinycell.
I divided the endships, fore and aft into a number of quadrangels. I took measures from the moulds. Of course a quadrangel can never be trusted therefore they were turned into triangels always reliabel. Measures were taken as good as possible. A pattern was made. The pattern was tried for accuracy and corrections were made, then the Divinycell quadrangel was cut out and hold in place with temporary scruvs. Then vedges were glued betveen the quadrangels, held in place with nails untill the glue set.
When the glue had set. Nails and screvs are removed. Next step is to shape the foam.
Here follows some pictures. Click on them once or twice to enlarge.
Yrvind Ten with all the Divinycell pieces in place.
Me next to the boat. Details can be seen of quadrangels and wedges and glue oozing out.
A closer look.
One of the pattern and a paper with the measurments. Note the small numbers at the edge of the pattern. It is the corections.
Se also this film
To be continued…