fweasel's V3 Zelos 36 build

[fweasel]

Been working on this spare Zelos hull from time to time while glue is drying on other builds. I gutted it completely earlier this winter, sanded the entire interior, and ground out all of the epoxy blobs along the seams. I dremeled out the stock motor mounts and left just the support for the stuffing tubes. Blank slate.

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The original owner of this boat flipped it on one of his first runs and knocked one of the struts off the hull. It tore a hole in the rear of the right sponson. I made templates and cutout 3mm carbon fiber plates to reinforce both strut mounting areas. I filled in the missing material on the right side with a second, smaller carbon plate, then epoxied it in place with JB Weld.

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[fweasel]

I stole some drawings from Mike W for a set of MBP Smart Drive adapters that Gabe at Stump Fabrication machined for me. Drilled three new mounting holes in each transom rear and reused the existing stuffing tubes. The new adapters bolted up to the rear of the hull with two new holes on each side. It was a lot of measuring to ensure the drives were installed perfectly parallel with the sponson tunnel.

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I drew up a design for a rudder extension bracket to keep the rudder behind the props and sent it to Stump Fabrication again. Since it was being made custom, I used it as an adapter to bolt on a 114 style rudder from CCFP. The bracket bolted up to the stock holes and the new rudder bolted up to the rear of the bracket.

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The new rudder needed longer hydraulic arms for steering. I cut the stock arms in half with a cutoff disc and extended them with 8mm carbon fiber tube. I got lucky with just some light sanding and a tight, interference fit. I pressed everything together in a vice with plastic jaws. The geometry worked out perfect and everything moves very smoothly.

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[fweasel]

Got everything mounted and lined up. Turned out pretty good and I think it will look better once I get the new aluminum parts powder coated black.

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Next up is reinforcement. I'm going to install carbon fiber tape along the side seams and across the rear of the hull and then do a full inlay across the bottom and up the sides. I'll probably cut out deck stringers from carbon fiber plate like I did on my existing Zelos which dramatically strengthened the top deck. Once the inlay is done, I can start on the solid motor mounts to prevent the motors from shifting. Lots of other projects in the shop at the moment. Luckily there's a global pandemic going on to free up some time.

[Revolt Flash]

Nice work Ryan.

[fweasel]

Nice work Ryan.

Thanks

[fweasel]

Got the inlay done. Considering a second layer over the tunnel to help support the weight of the batteries. I did strips along the rear and side seems first, then one large piece across the bottom and up the sides. Poured chopped fiber and epoxy into the tips and across the deck bridge. Filling in the rudder standoff with the same mix now and installing blind nuts for the rudder hardware.

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[fweasel]

And the aftermath on my workbench

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[Bp9145]

And the aftermath on my workbench

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Hey Ryan, do you realize that bottle of isopropyl alcohol could buy you a new Zelos. LOL

[fweasel]

Hey Ryan, do you realize that bottle of isopropyl alcohol could buy you a new Zelos. LOL

But what would I thin my epoxy with?

[fweasel]

Not much progress here since I've gone back to work. I did get my parts back from powder coating. They turned out pretty slick.

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[Mike W]

Run it! 😁

[fweasel]

Run it! 😁

The only way this boat will run is if I I take it with me jogging. Probably won't get to the motor mounts until winter. Or, the next pandemic.

[Neubs]

fweasel - Have you made any progress on the Zelos? I see the last post was from 2020....

[fweasel]

fweasel - Have you made any progress on the Zelos? I see the last post was from 2020....

No, I sold the boat before it was finished. Too many other unfinished large hull projects in the workshop.