Here we are measuring to cut pieces for the centerboard. The lead sheet is 1mm thick, 2.5lb/sq ft. I am installing 8 pieces per centerboard side, 100mm x 400mm each.
I clamped router guide boards for the sides of the cavity, and did the shorter ends free-hand. The cavity will be just under10mm deep. By looking at the reverse (shaped) side of the board half, I could determine from the laminate pattern (sort of like reading tree rings) that the board half was about 14mm thick at the thinnest point in the cavity.
Then, a stack of 8 lead sheets was laid one at a time into the cavity, painting a bit of straight epoxy on the upper surface of each sheet.
After all sheets were in place, I then poured straight epoxy around the edges of the lead until the cavity wouldn't take anymore.
You can see the rudder getting the same treatment. The centerboard is getting about 17lb of lead total, and the rudder about 2lb.
The halves were then joined, placing two locating dowels in holes that had been drilled previously, to provide correct alignment of the halves.
Lots of clamping force to make sure that the bowed halves join together well.
Meanwhile, there are more coats of epoxy to apply to bulkheads, and other pars. And fiberglass to be applied to the inside of the centerboard trunk pieces - in a future article.....