Kemosabe Hardtop, Part 2

Kemosabe’s new hardtop is coming along great.  Recall, Part 1 of our project blog last month covered all initial materials, design and construction of the hardtop through two complete layers of glass/epoxy on the underside and topside where we left off.  Since then, we have sanded a ton, faired, glassed, sanded and sanded some more.  Learning as we go is an understatement and we are psyched to share project update Part 2 with you here.  Check it out.

Kemosabe Hardtop, Part 2:
TotalFair was used on the underside of our top wherever the more significant construction went down to support the pipework.  The TotalFair here was awesome as a profiling filling and fairing putty that mixed well, feathered well, and did not pinhole.  The areas that are green in pictures below are where we used TotalFair.  Once cured, we sanded and prepped both the underside and topside with layer of TotalBoat 5:1 Epoxy mixed with phenolic microballoons, shown in pictures as the overall brown coating that was perfect once cured to sand to a consistent smooth surface all around.

As time and scope is always the name of game with any project, we were multi-tasking throughout this sanding & fairing part 2 phase of the project.  As the fairing compound was curing and in between initial fairing/sanding coats of microballoons, we built our light boxes.  The pictures below show the basic construction, glassing, fairing and sanding of the light boxes.   We added the boxes to the top during final stage of Part 2 in order to complete the final fairing coats of epoxy/microballoons over the entire underside with everything in order to sand smooth all together.

With the topside and underside completely faired and sanded we are on to the next phase of project….   the edges and paint prep…  stay tuned.

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