R42 BUILD PROJECT GALLERY

See the R42 Design Page here

The beams are symmetrical about the athwartships axis and so one set of female tools can be used to build all of the beams. These are the fairings and they are non structural so the laminates are quite light. The primary beam is a box structure that sits inside the fairings.

Above; Consolidated laminate in the cabin top for the dagger case.

Hull fairing and vac laminating the internal deck laminate

In these images below; the laying up and vacuum laminating of the forward beam bulkhead and reinforcing material in the hull. The bulkhead laminates are critical to carrying the loads around the door opening. The laminates have been clearly marked on the laminating table for fibre type, stack numbers and orientation.

In the top photos the beam fairings for the forward beam. The top fairing shell is just 12kg

Main hull deck ready for internal laminate

Main hull deck being turned. Placement for winches and sail controls clearly marked.

Hand laminating the external laminate over the carbon planks on the cabin top

The planking material is made up of Divinycell PVC Core with uni carbon laminates on each face manufactured under pressure by ATL Composites to ensure a consistent laminate with a high fibre ratio.

The laminate is supplied in 1.2m x 2.4m panels  with a Z join at each end.

They are bondedwith epoxy using ATL's Z press which applies pressure and heat to the  join allowing it to cure in just a few minutes.

The panels are progressively moved along until a panel the full length of the hull is created.

The full length panels are then ripped into strips that you can see being planked in the photos. Finally an external laminate is applied.

Mould frames and strongbacks are made from 16mm mdf CNC machined by ATL Composites. The cutting files provide slots for fast assembly and the building forms are stabilised by locking the joints with epoxy fillets.