What is KSS
KSS – KELSALL SWIFTBUILD SANDWICH
Paul with 20ft Skiff hull built using the KSS method in 3 days
This Photo give you a fairly good idea of the results from a 3 days workshop. Here
you see a 20ft hull, showing temporary supports which are later removed once the
shape has been locked in by fiber glassing the foam along the area of bend.
Notice the high gloss table to the right, where the 2 hull panels were fabricated.
Note the deck edge radius on the top edge of the panel makes for a smooth transition
from the panel to the top. Note also that the wooden formers role is to provide purchase
to pull the full into shape, and keep the beam in check.
Lets review the process.
First we start with a high gloss table, mark it out, and first paint the gel coat onto the table
where the flats of the side panel will be. The Gel is left to cure overnight.
Then we add the molding for the deck edge radius, and prepare to resin and lay cloth into the
curve of the deck edge radius.
The deck edge radius is first covered with packing tape with a high gloss finish to act
as a releasing agent.
This photo give you a good idea of the layout. Notice the plastic sheeting along the side
of the table, which will be used later for the vacuum bagging. The process relies on team
work, for everything to move forward smoothly, and usually the second panel takes about
half the time of the first when conducting a workshop with a new group.
Now we have completed laying the chop strand into the deck edge radius, we have
covered the gel coat with resin, now we roll out the fiberglass along the length of the
hull. The glass is precut to the table markings.
The Glass is rolled, with paint rollers to lay down the resin, followed by metal rollers to
remove any air bubbles from under the cloth. Next we lay down the precut foam onto
the cloth, then we vacuum bag.
Plastic fencing is laid out over the foam, and a standard shop vac is used to remove
the air from the system which applies an even pressure across the whole of the panel.
Note the dark patches of excess resin coming to the top of the panels as a result of
the vacuum applying a uniform pressure across the length of the panel.
The vacuum connection is made by cutting the top of a 2 litter juice bottle, which seems
to provide a good connection with the flexible hose from the shop vac.
This photo shows the effect of the plastic fencing, not 2 layers are offset to allow for
airways to form to allow the vacuum to remove air from the length of the table.
The Thermometer is used to monitor temperature along the length of the table. You can
also see the resin seeping up through the fencing.
Good timing makes for an easy job to remove the excess resin after the vacuum has
completed its work. The resin needs to have gelled, just enough for a firm bond, but
still soft enough to make easy cleanup work.
The electric EZ cutter makes light work of the fiberglass cutting, a worthwhile investment.
Here its being used to trim of the excess glass along the markings on the table.
Now the moment of truth, as the first panel is released from the table in preparation for
Turning over for all to see. Note that the table was covered with 4-5 layers of releasing wax
prior to the laminating work, you cannot rely on the gloss alone to allow the panel to release.
The edge is rough at this time, and will be trimmed later once the second panel has been
laminated.
Gloss and smiles, as the team sees its handy work. This photo does not do the finish
justice, what you are looking at is a production quality finished, gelled first panel.
Plenty of time to explain the process while we wait for the second panel to complete
its vacuum process.
Once the panels have been completed, they are trimmed for symmetry, then grooves are
cut to assit shaping.
Here you see the "T" bar being used to align the groving which is achieved by using
a rotary hand saw. Several slots are cut which will enable the foam to bend to form the
camber of the underside of the hull.
Its not all laminating work, here you see members of the team cutting wood for later
forming the hul shape.
Here you can see the panels have been put together, still flat, and the "T" bar is in position.
Also you can just see the slots that have been cut into the hull to help with the shaping.
The panels being reasonable light, were raised onto a temporary platform to make
the next part of the process easy. The edges are gently pulled apart and the wooden
formers are inserted at the stations along the hull and attached using rope to the underside
of the "T" bar. Gently the ropes are tensioned in turn at each station as slowly the panels form
a hull shape. This part of the process takes about 15 minutes.
Here you see Derek Kelsall inside the hull. Note the ties hanging down which are attached
to the "T" bar at each station. Now just the wooded battens to be attached, and the ropes
tensioned.
Here is the photo of the shaped hull with wooden battens.
Completed! Thats it, want to come and find out more? Sign up for a workshop?
Check out the More Information page.
