{"id":5074,"date":"2025-11-22T13:30:40","date_gmt":"2025-11-22T23:30:40","guid":{"rendered":"https:\/\/www.svyohelah.com\/wordpress\/?p=5074"},"modified":"2026-04-22T15:20:30","modified_gmt":"2026-04-23T01:20:30","slug":"weeks-6-thru-8-fiberglass-fillets-and-fairing","status":"publish","type":"post","link":"https:\/\/www.svyohelah.com\/wordpress\/archives\/5074","title":{"rendered":"Weeks 6 thru 8 &#8211; Fiberglass, Fillets and Fairing"},"content":{"rendered":"\n<figure class=\"wp-block-image size-full\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7236.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"800\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7236.jpg\" alt=\"\" class=\"wp-image-5082\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7236.jpg 600w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7236-225x300.jpg 225w\" sizes=\"auto, (max-width: 600px) 100vw, 600px\" \/><\/a><\/figure>\n\n\n\n<p>While we toured around South America (including walking on Cape Horn!), Ethan and Michael continued the hard work on the decks.  Above is a pic of what he described as his &#8220;arsenal of longboards and blocks&#8221;.   He continued to send me snippets and pix, and I&#8217;ll try and get those into these next posts in a way that makes sense.  I&#8217;m sorry we weren&#8217;t closer and keeping up with the progress, but our trip dates couldn&#8217;t be changed.  Ethan did the best he could to keep us updated even though our bandwidth was less than stellar at times.  <\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184311.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184311-768x1024.jpg\" alt=\"\" class=\"wp-image-5088\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184311-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184311-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184311-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184311.jpg 1536w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>When we left off last time they had patterned and were cutting the fiberglass sheets.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large is-resized\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182729-1.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182729-1-768x1024.jpg\" alt=\"\" class=\"wp-image-5089\" style=\"width:840px;height:auto\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182729-1-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182729-1-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182729-1-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182729-1.jpg 1200w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>In addition to the fiberglass they also cut some peel ply.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182733-1.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182733-1-768x1024.jpg\" alt=\"\" class=\"wp-image-5090\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182733-1-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182733-1-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182733-1.jpg 960w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>What is that?   To google for an answer:  &#8220;Peel ply is\u00a0a fabric layer placed over a composite laminate during curing that leaves a textured surface when removed. It saves time by reducing or eliminating the need for sanding, provides a surface ideal for secondary bonding, and holds excess resin, volatiles, and air. It&#8217;s a common material in industries like aerospace, automotive, and marine engineering where high-quality finishes are important.&#8221; <\/p>\n\n\n\n<p>How it&#8217;s used<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Apply fiberglass and resin as you normally would.<\/li>\n\n\n\n<li>Lay the peel ply smoothly over the wet laminate.<\/li>\n\n\n\n<li>Use a plastic spreader to ensure good contact and remove air bubbles.<\/li>\n\n\n\n<li>Allow the composite to cure completely.<\/li>\n\n\n\n<li>Peel off the peel ply, ideally at a sharp angle, to reveal the finished surface.\u00a0<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182755-1-scaled.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182755-1-768x1024.jpg\" alt=\"\" class=\"wp-image-5095\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182755-1-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182755-1-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182755-1-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182755-1-1536x2048.jpg 1536w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182755-1-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>First they lay a coat of resin followed by fiberfiller to fill all the holes.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182802-1.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182802-1-768x1024.jpg\" alt=\"\" class=\"wp-image-5096\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182802-1-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182802-1-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182802-1-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182802-1.jpg 1536w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>Then two piles of 1.5 ounce matt and a peel ply while the fiberfiller is still wet.   They do staggered butt joints to reduce fairing.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182901.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182901-768x1024.jpg\" alt=\"\" class=\"wp-image-5101\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182901-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182901-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182901-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_182901.jpg 1536w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>Port side deck glassed, bye bye leaky deck prism.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184414.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"480\" height=\"640\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184414.jpg\" alt=\"\" class=\"wp-image-5103\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184414.jpg 480w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251011_184414-225x300.jpg 225w\" sizes=\"auto, (max-width: 480px) 100vw, 480px\" \/><\/a><\/figure>\n\n\n\n<p>And the foredeck glassed and second prism gone.   <\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7214.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7214-768x1024.jpg\" alt=\"\" class=\"wp-image-5084\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7214-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7214-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7214-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7214.jpg 1536w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>Next they laid fairing compound on the decks.  Google tells me:  &#8220;Fairing compound is\u00a0a putty-like substance used to fill and smooth surfaces, making them level and even. It consists of a resin mixed with fillers, giving it a peanut-butter-like consistency that is easy to apply and doesn&#8217;t sag on vertical surfaces. It is used for cosmetic repairs, structural fixes, and can be used on various materials, particularly in boat building, where it&#8217;s common for both above and below waterline applications.&#8221;<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7218.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"800\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7218.jpg\" alt=\"\" class=\"wp-image-5107\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7218.jpg 600w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7218-225x300.jpg 225w\" sizes=\"auto, (max-width: 600px) 100vw, 600px\" \/><\/a><\/figure>\n\n\n\n<p>Since the purpose of fairing is to create a smooth surface, lots of sanding is involved during this process.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183438.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183438-1024x768.jpg\" alt=\"\" class=\"wp-image-5108\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183438-1024x768.jpg 1024w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183438-300x225.jpg 300w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183438-768x576.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183438-1536x1152.jpg 1536w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183438.jpg 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/a><\/figure>\n\n\n\n<p>This is the foredeck and side decks after being faired.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7239.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7239-768x1024.jpg\" alt=\"\" class=\"wp-image-5109\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7239-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7239-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7239-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7239.jpg 1536w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>Then it&#8217;s time for the fillet, which Ethan does with a master wax fillet ball.    What is a fillet?   It&#8217;s the rounding of an interior or exterior corner<em>.<\/em><\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183448.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183448-1024x768.jpg\" alt=\"\" class=\"wp-image-5110\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183448-1024x768.jpg 1024w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183448-300x225.jpg 300w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183448-768x576.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183448-1536x1152.jpg 1536w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_20251114_183448.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/a><\/figure>\n\n\n\n<p>Now it&#8217;s time to cut the scuppers down to the level of the new deck.  I would be terrified to make this first cut, but Ethan knows how these boats are built and where and how he can hack into them.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7243-scaled.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7243-768x1024.jpg\" alt=\"\" class=\"wp-image-5111\" srcset=\"https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7243-768x1024.jpg 768w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7243-225x300.jpg 225w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7243-1152x1536.jpg 1152w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7243-1536x2048.jpg 1536w, https:\/\/www.svyohelah.com\/wordpress\/wp-content\/uploads\/2025\/11\/IMG_7243-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/a><\/figure>\n\n\n\n<p>And here we are with the fillets, scuppers and decks faired.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>While we toured around South America (including walking on Cape Horn!), Ethan and Michael continued the hard work on the decks. Above is a pic&hellip;<\/p>\n","protected":false},"author":3,"featured_media":5108,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[65],"tags":[],"class_list":["post-5074","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-teak-decks"],"_links":{"self":[{"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/posts\/5074","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/comments?post=5074"}],"version-history":[{"count":12,"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/posts\/5074\/revisions"}],"predecessor-version":[{"id":5113,"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/posts\/5074\/revisions\/5113"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/media\/5108"}],"wp:attachment":[{"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/media?parent=5074"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/categories?post=5074"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.svyohelah.com\/wordpress\/wp-json\/wp\/v2\/tags?post=5074"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}