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WESTSAIL 42 CONSTRUCTION MANUAL-' ;

INDEXBasic Materials and lisage Options Lists and Prices Basic Specifications and Prices Standard Accommodations & Specs Router Pattern Numbering System Router Scheme Fastener Assortment Prefab Wood Parts

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lAl lA2 lA3 lAS lBl lCl lDl lEI

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PREPARAnON, HUI,.L AND DECK

l4 2. c2Al 2A2 2A2 2A3 2A4 2A5 2A6 2Bl 2B3 2B4 2Cl 2C2 2C3 2Dl 2El 2Fl 2F2 2F3 2F4 2F5 2Gl 2Hl 2H2." ,'.

Cradle, Steel Leveling Hull Steel Ballast Lead Ballast Hull Flange Beam Adjustment Keel Dam, Gudgeon..,;. \.

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Rudder and Rudder Installation Steering System Emergency Tiller

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Main Bulkhead Installation and Bonding Subfloor Bulkheads Cabin Sole Plywood Main Mast Step Installation Mizzen Mast Step Installation Hull to Deck Joint Port Lights and Windows Cabin Overhead

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INTERIOR CARPENTRY Forward Cabin & Chain Locker Head Compartment Forward Lockers Main Cabin Mast Support Post Berths and Settee 3Al 3Bl 3Cl 3Dl 3D2 3El,

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Bobstay Stem Fitting Bobstay Fitting Installation Chain Plates & Installation Thru Hulls ano--Seacocks Hawse Pipes and Deck Scuppers

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Wood Parts Details Center Table Dinette Galley, Icebox Companionway Steps Chart Table Teak Cabin Sole Cabinet Trim & Miscellaneous Doors Drawers Engine Room Aft Cabin

3F l 3Gl 3Hl 311 3Kl 3Ll 3Ml 3Nl 3N3 3N9 301 3Pl

Teak Decks Scupper Grates Bowsprit Bow Pulpit Anchor Roller Staysail Pedestal Stainless Boomkin for Yawl

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Propane Tank Deck Box Traditional Side Lights Belaying Pin Rail--. - -

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Stanchions Lifelines Bow Pulpit Mast Rails Boom Gallows Stem Pulpit Windlass Anchors

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Staysail and Backstay Plates Sheet Blocks and Travelers Genoa Gear Winches and Cleats Spinnaker Gear Mizzen Staysail Gear Mooring Cleats Vents

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l4 24 Fl 4F2 4 F3 4F6 4F12 4El 4E2 4Gl 4Hl 4H3 5AI 5A2 5A2 5A3 5A4 5A5 5BI 5B5 5CI 5C2 5C7 5C8 5CIO 5Cll 5Dl 5D4

Caprail and Rubrail Cockpit Teak Slats Companionway & Hatch Forward and Aft Hatches

.c4Al 4Bl 4Cl 4Dl

EXTERIOR CARPENTRY

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PLUMBING

Deck Prism Vane Steering Companionway Dodger Outboard Motot Bracket

5D5 5E l 5G1 5Hl

Prop and Shaft Engine Installation Engine Water Plumbing Engine Exhaust System Engine Fuel System Engine Instruments and Controls Engine Electrical Spare Parts List ELECTRICAL

MECHANICAL

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Mizzen Mast Spreaders Mizzen Boom Main Boom Staysail Boom

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Main Mast

Mast Bases

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RIGGING

Mast Light Wiring Lightning Protection

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12 Volt Electrical Electronics 110 Volt Electrical

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Rig Standing Rigging Running Rigging

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l4 2. co m7Al 7Bl 7Cl 7C2 7C3 7DI 7El 7FI 8AI 8B l 8CI 8Dl 8D2 9A2 9Bl 9B2 9B3 9B4 9B5 9B6 9CO 9CI 9C2 9C3 9C4 9C5 9C6 9DI

Diagrams - Fresh Water Pumps and Thru Hulls Bilge Pumps Heads, Waste and Drains Cockpit Drains Tanks, Water, Fuel, Holding

6Al 6Bl 6B7 6Cl 6C8 6D l

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,GEL .COAT. a.

Surfcing - used for Einish which can be sanded easily . Laminating resin camlOt be sanded to give smooth surface .Surfacing agent added to laminating resin achieves he.

Laminating - basic resin for laminating hulls,. decks, small parts Pond for. bonding. Catalyze \>lith 'r-1EI< pe1;'oxide at ambicn temp. of 770 F. 1.0% NEK will gel in 25 minutes. ' 1_0% 'equals 38 cc t-1EK per gallon of resin. A 10# can almost full is approximately 3/4'gallon, and needs about 30 cc ' of catalyst.. "

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1.'

. RESINS

BASIC t-l\TERJ hL.') REOUIRED AND USAGE PO'LYESTER. .

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same result.

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MOLD RELEASESa., ..

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a liquid sprayed' on mold 'surfaces t o facilitate PVA f:lust. be the easy 'removal of molded parts from molds. sprayed over exterior gel coat appli.cations to obtain . . a proper cure. ,.;'" . ....; . . ' . '.

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.Mold release wax - applied to mold s u r f a c es tc? . prevent Can a lso be applied to any adhesion'or el coat to'mold surface where easy removal of,excess resin ..... r.equired .. , , . '

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fections.

b.

sprayed with PVA.

Raman'el - air-curing gel coat used, .for boot. stripe and sheer strie.

When used on exterior'sUrfaces,

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12 to 15 mils thi k on hull, deck Thinned with 1;'1 styr.ene/acetone for spraying 'consistency, used for touch 'up of centerlin e and imper, .

'and .parts.

Mold '-':' gel.,

oa t . spra'yed

it must be

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, CATALYSTS

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MEK peroxide 'is the ,only cOll1l1!only'used catalyst.

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DESCFU?TION

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ASBE S TOS MISH-M.l\SH, a.

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to reduce

CABOSIL

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putty-liKe consistency.

A,white p ow d e r mxed with r e sin to substatiallY'

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- w()od _to _fiberglass.

.surfaces.

Thick- mixtures are e asi er' .to use ,on ve r t ic a l or near-:vertical_

added

If very think build-up is a nt ic ip ated , -

It is used to bpnd fiberglass to fiberglass and/or . -

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f powd e r ed asbestos a d eSl.n. Powdered a sbestos is with resi n to the requ ir ed' c9 rsi ste ncy e ith er very thick, "syrupy, or anywhere in between' d ep e n d n g upon use and preferencd.

A' mixtu re

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A c et o n e - commonly us ed to clean brus hes and 'other tools and' .hurilan hands too, although you 'should make s1.1re,tht acetone does not adversly effect y our sIan b e fore using it to ,any great xten. CAPTION: ACETONE IS HIGHLY FLAt-1MABLE. , '

may be thinned with, a by weightSt y e ne

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used to

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viscosity of resin and gel coa t . Gel coat styrene aceton mix at no more 'than 10% '

chopped. 'strand s h oul d be

MICRO-BALOONS

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to fill hull or-deck imperfections. '- As.its -main use is'for repair' surfacing agents should be added.'

be

mixed_with a little

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to san d .

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Light weight r ed powder mi xed with resin and-used t o fill' v o d s Very easy o r bonding. w ood or fiberglass prior to

amiating.'

GLUES

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to t able and

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i esserttial.

Wel dwoo d contact cemC:!nt

Used on

i n te l;'i or \.. ood-to-wood j oin t s . Should not be u se d on teak \'liping completed joints vudl t-lith damp rag before, exterior joints.

\eldwood plastic resin g'lue . ,- mixed a ccor d in g to container

c ount e r tops. '

(or similar produc-t)

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Strict-adherance

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SOLVENTS

a.

,be thorou hly mixed with r sin or gel: coat, as notd in l , : . but for \11 l.dely varyl.ng ambl.ent temperatures, the mixture may be ' : vrl.ed from Sec/gallon ? 80 ee/allon to, a qui r e the desired gel tl.e. NEK can be used, W1 th acc e .L. e ra tors, such as Dt'1!\ if necessaly, hOtl1cver THE ACCELERATOR IruST BE 1'1IXED INTO RESIN INDEPENDENTLY OF, If' the 1:\110 (the acceleJ:'ator and catalyst) a:t'e mixed THE CATALYST. t oge th er a nice explosion, \l1ill l ik e ly be the result!

pat,

thi k en

gel coat

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to c o n tainer instructionfor cementing form ca

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a white sealant \'lith e)::celent 'G. E. Silicone Seal Its quj.ck, curing time re?:lke' it bonding propez-ti'cs. useful ;fer seaing cabinet to formica jcj.nts in galley '-'/here water secpt.ge is. a problem.

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Interior p2.::t a:::-e ir..stc:1led T fstening to !Jul}:he2ds or to other The portion of bulkhc"d or other p3rt 'V..'hi.ch adjoint> the ' parte. fiberalass hull or deck i.e bnded, using rccin ad i.bcrglucs cloth , and'mat. For bondi.ng \'lOGa::n par-c:::; -.:.0 hul..!-, Uri .2 .J..c:.y,,;;r., of 6' l!at (l oz.) and 1 12.yer c 8 h Cloth 'rpe (7 02.) "ihc:;:6VE:r pOD S ihJ_0 on both II J:or ext:rc::e ct:CC':i:lg bQhdi.ng, one mi.!ht u::;e 1 .layer of 6 sides. Fab mat (l!i oz.) togethc.:r v.!ith 20 oz. roving and 1 lyer of a" cloth tape.

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Grove Special ties Flo-Caulk a b\'o part' caui1:ing compound used on dec}:ing. It cures in much shorter time (hours) than Boat Life'. It aso requires a primer on .. oily woods.-

cure.

ai l4HOv TO POND

'BOilt Life life cauk availtlble in'three colors, black whi te and mahogany. Blac1 is used to caulk decks, sea bolts, on gudgeons, bed shaft log and,thru hull fittingsp l'fuite Boat Life co;.n be used \-rhere \-White color is desired. Both colors availble.in iquidf9rm which is excellent for fiJ:ing leak3 as it f1.c;.m easiy. \'fuen usee! on oily \'Ioodz such as teak, Boat Life pri,'ner [Uus t be used to maximize adhesion. Boat Life ,needs about one week to,

.

2. cA.

Dolfinitc all purpic bedding copound used on al fi ttings and "lood pZ;.r'cs i tted to deck or hul.l, such as teak decking to ib:::rglas, under cap rail.s and rub rails, uner pintlcs and glldgeons,'under deck hrdware, etc. fF2QOS is the r.'.ost COIT":l!lO!l co:npound, 3905-'l'X is a fungicide cOiCpound c= uee \=!here maximum resistance to rot' anddew is desired.-

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uv,rG (,,0

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tlela"ood Resorcinol plastic resin gl.ue must be rrixed according to contin0r instructions. Uaed on teak ex terior jOints,' Zlnd on sul:.zt.egerl or continually \, ' 950. oCi Co m m issio n i n g i n c l u d i n g sea trial 1 72.00 - . ' (Cru isi ng Centers). Cross cou ntry pa ckagi n g Crad l e (refu ndable on ret u r n )

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l4 2. co m1 250.00 ' . 3320,00 -.":, /.

650.00 . 1 7 5.00 600.00... ...:.-

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$45,950.00

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PART NUMB E R

WESTS81GAPP L I CAT ION

PA R TS O R MAT E R I A L L IST

27 5 M cCormick, P.O. 80x 1 82 8 Costa Mesa, Cal ifornia 92626 Telephone: ( 7 1 4) 54997 1 1

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PARTS OR M AT E R I A L L I ST

275 McCormick, P.O. Box 1 828 Costa Mesa, Cal ifornia 92626 Telephone: ( 7 1 4) 54997 1 1

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R E V ISIONS

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