posted 02-21-2000 11:09 AM ET (US)
Thomas - My wife and I spent a better part of a day in 1977 (honeymoon...I know, just how many of us had even thought about going to the plant on their honeymoon?) taking a tour with Bob Dougherty at the BW plant out east. We watched the "birth" of a 17 hull. It wasn't all slop and glop, but it wasn't pumped in either. Here's what I remember:
The two molds were called in the factory, the bathtub and the turtle. Bathtub was the mold for the outer hull, turtle for the inner hull. Both on wheels. While the turtle was being layed up, it was on the wheels. When it came time to foam, the turtle was picked up by a crane at the stern and bow, pivoted 180 (turned turtle?) and the bathtub was manuvered under it, and the turtle was lowered, and the front (bow) wheels were set onto a set up wooden blocks (more later).
Clamps applied along the gunnel. "Snake holes" (another factory term, remembered for two decades) made about every 18" along the gunnel. The molds were rolled over to a gantry type operation, where a few buckets were being prepared. Temp and humidity were noted, and figured into the mix (the speed in which the foam would react was dependant on this). A spade handled drill with mixer attachment was used. And what looked like a REALLY big plunger. And the pour hole was down a 6" shaft in the turtle, that ended in the anchor locker.
Now this is where it got reallll interesting, real quick:
There were between four and six guys doing the foaming;
One guy directing from the gantry, calling off the time.
One guy pouring the contents togeather.
One guy running the mixer.
One guy to handle the mixer, once done.
One guy ready with the plunger.
Mixing would start, counter calling off the seconds. When he called the time to stop mixing, drill came out of the 5 gallon bucket, mix poured, and remains squeeged out and down the foaming shaft. Last action was for the plunger to get rammed down and hydralically clamped to the mold.
For a BW guy, it was poetry in motion....
Within about a minute you could hear the whistling of the expanding foam shoving out the air from the snake holes. When all the snake holes filled with foam coming out, they knew that the hull was completely filled.
After about five minutes, the turtle was removed, and ya got a new hull.
I asked how long did it take for them to get the proper angle for the foam to run to the back. He said that was one of the harder things to figure out, as they also had to factor in the temp/humidity too.
He also mentioned that about every other month or so, the foam would go off, before the plunger was clamped and it would take a day to clean foam off the mold, gantry,people, etc.
Probably more than anyone wanted to know about the process.
Don