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Thread: fweasel's V3 Zelos 36 build

  1. #1
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    Default 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)

  2. #2
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    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)

  3. #3
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    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 at 01:17 PM.
    Vac-U-Tug Jr (13mph)

  4. #4
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    Aug 2015
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    VA
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    Default

    Nice work Ryan.

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

  6. #6
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    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)

  7. #7
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    And the aftermath on my workbench

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

  8. #8
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    Quote Originally Posted by fweasel View Post
    And the aftermath on my workbench

    IMG_20200425_172207.jpg
    Hey Ryan, do you realize that bottle of isopropyl alcohol could buy you a new Zelos. LOL

  9. #9
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    Quote Originally Posted by Bp9145 View Post
    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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