Building the Tunnel Mite

Work is progessing nicely on the bottom. Had to have two hands laying in the tunnel runner and the tunnel sides. Made templates for the sheer and chine (along with the tunnel sides). I found that I have more than enough time to work with the Poxy-Grip, no problem there. It's starting to get cold here in Baltimore, so I'm having to use the garage heater (can't wait to see that electic bill). Oh well... I have found that for me it is better to over-cut everything by a quarter inch, fit and then resize. My rolling jig is working fine and really helps out when I am working by myself, which is most of the time. For any sanding or cutting I can roll it outside and then blow all the dust away with the leaf blower. Better to keep the work area clean.
Things I have learned:

  1. Have a pat answer as to why I just didn't buy a jet-ski.
  2. Under-estimated the amount of Poxy-Grip that I will need (I always coat both sides of anything I am fastening).
  3. Poxy-Grip is better to remove from garage floor AFTER it has cured. (comes up better in lumps tham when it is smeared).

Moving along... Bending the chines and sheers demanded a little more attention to get it right, but after a little time and a little ingenuity with clamps, it came together. Again spacing of the fasteners is important. After fitting and sanding and filling in countersinks, inperfections and goof-ups, is was time to primer. I used the System-Three from Glen-L. Three coats later, it was finaly starting to look like something that would actually float.
Things I have learned:

  1. You NEVER have enough clamps
  2. Don't screw in a screw and hold you finger underneath to see if it comes through.
  3. Primer the tunnel and sides first, that way you don't have reach over wet primer.
  4. I used a three inch short-nap roller to apply, then drug a 4 inch brush lightly over to smooth and remove air bubbles ( works great).
  5. Ripping a mahogany board makes a very fine saw dust, mixing a little with some Poxy-Grip makes a great filler.

I decided to completely finish the bottom before attaching the top. I attached the spray-rail. I am trying to decide on a color scheme, I researched vintage hydros on the Internet, and have come down to using Blue, Yellow and Red. I'm thinking of leaving the cowling natural... will decide that later. Anyway, after 3 coats of paint, using the same method I used for the primer, I applied the blue to the bottom, painted the spray-rail red and will add some yellow striping later.
Things I have learned:

  1. Keep your dog out of the garage when painting.
  2. Open a door.
  3. Buy at least 10 one inch throw-away brushes.
  4. Wear clothes you are not attached too. I just noticed I have mis-spelled Tunnel-Mite in all my E-mails... really should use spell check.