fweasel's V3 Zelos 36 build

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  • fweasel
    master of some
    • Jul 2016
    • 4282

    #1

    fweasel's V3 Zelos 36 build

    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.

    IMG_20191027_172420.jpg IMG_20191027_172406.jpg IMG_20191027_172459.jpg

    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.

    IMG_20200329_163318.jpg IMG_20200329_163333.jpg
    Vac-U-Tug Jr (13mph)
  • fweasel
    master of some
    • Jul 2016
    • 4282

    #2
    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.

    IMG_20200131_155732.jpg

    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.

    IMG_20200229_201539.jpg IMG_20200229_201645.jpg

    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.

    IMG_20200420_203416.jpg IMG_20200420_203449.jpg
    Vac-U-Tug Jr (13mph)

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    • fweasel
      master of some
      • Jul 2016
      • 4282

      #3
      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.

      IMG_20200420_202413.jpg IMG_20200421_215026.jpg IMG_20200421_215128.jpg

      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.
      Last edited by fweasel; 04-23-2020, 01:17 PM.
      Vac-U-Tug Jr (13mph)

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      • Revolt Flash
        Senior Member
        • Aug 2015
        • 437

        #4
        Nice work Ryan.

        Comment

        • fweasel
          master of some
          • Jul 2016
          • 4282

          #5
          Originally posted by Revolt Flash
          Nice work Ryan.
          Thanks
          Vac-U-Tug Jr (13mph)

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          • fweasel
            master of some
            • Jul 2016
            • 4282

            #6
            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.

            IMG_20200424_152959.jpg IMG_20200424_164012.jpg IMG_20200424_170125.jpg IMG_20200425_162430.jpg IMG_20200425_172227.jpg
            Vac-U-Tug Jr (13mph)

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            • fweasel
              master of some
              • Jul 2016
              • 4282

              #7
              And the aftermath on my workbench

              IMG_20200425_172207.jpg
              Vac-U-Tug Jr (13mph)

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              • Bp9145
                Fast Electric Addict!
                • Jan 2016
                • 1466

                #8
                Originally posted by fweasel
                And the aftermath on my workbench

                [ATTACH=CONFIG]168819[/ATTACH]
                Hey Ryan, do you realize that bottle of isopropyl alcohol could buy you a new Zelos. LOL

                Comment

                • fweasel
                  master of some
                  • Jul 2016
                  • 4282

                  #9
                  Originally posted by Bp9145
                  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?
                  Vac-U-Tug Jr (13mph)

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                  • fweasel
                    master of some
                    • Jul 2016
                    • 4282

                    #10
                    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.

                    IMG_20200604_222937.jpg
                    Vac-U-Tug Jr (13mph)

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                    • Mike W
                      Senior Member
                      • May 2018
                      • 345

                      #11
                      Run it! 😁
                      Otto RC Marine

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                      • fweasel
                        master of some
                        • Jul 2016
                        • 4282

                        #12
                        Originally posted by Mike W
                        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.
                        Vac-U-Tug Jr (13mph)

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                        • Neubs
                          Senior Member
                          • Nov 2011
                          • 154

                          #13
                          fweasel - Have you made any progress on the Zelos? I see the last post was from 2020....

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                          • fweasel
                            master of some
                            • Jul 2016
                            • 4282

                            #14
                            Originally posted by Neubs
                            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.
                            Vac-U-Tug Jr (13mph)

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