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V. CONSTRUCTION
HULL
The Cape Dory 270 hull is molded in one piece using alternating layers
of hand layed fiberglass rovings and mats bonded with lightweight
polyester resin.
Into the open hull mold, white gel coat is sprayed over the entire
surface to an approximate thickness of 22 mi1. A dark-colored backing
coat is then applied on top of this for air detection during subsequent
layup.
The first layer of glass is 1.5 oz/sq. foot mat.
After this successive layers of 2410 Promat (24 oz/sq. yard non-woven
bidirectional roving with a 1.0 oz/square feet mat backing) are hand
laminated into the hull mold. The final result is a strong quality
lamination with proper glass to resin ratio.
The centerboard trunk and pin tubes are molded integrally with the hull
and are built up with the same layers of 2410 that the rest of the hull
bottom laminate is comprised of.
The hull topside laminate is molded inward on to a mold, forming the
internal flange which makes up the hull portion of the hull/deck joint.
(see drawing detail)
DECK AND HEADLINER
The deck is also laminated by hand in an one piece mold to produce the
shiny white and molded in non-skid surfaces.
After the gel coat has been applied to the mold, a backing of 1-1/2 oz.
mat is layed over it. In addition, along the vertical sides of the deck
house a 2.0 oz. promoted mat is used. This layer of promoted mat
prevents roving print through into the gelcoat from latter layers of
reinforcing.
After the promoted mat is applied, a layer of 1-1/2 oz. mat is applied
to all horizontal surfaces into which 3/8" thick end grain balsa panels
are placed and pressed.
At this point, plywood coring is also located and placed for eventual
through bolting of deck hardware. Finally, 2 layers of 1808 Promat are
applied. Aluminum plates, which form backups for other deck hardware,
are glassed in place at this point. Unidirectional roving is added to
reinforce areas subject to stress cracking.
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The headliner is molded on a textured female mold. A layer of antique
white gelcoat is sprayed over the mold. This gel coat after curing is
reinforced with 2 layers of 1.5 oz mat and a layer of 18 oz woven
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