Building an El Toro Mold.
I’ve always wanted to try making a fiberglass boat.  Well, here was my chance. Tony (Co-worker & Foredeck for No Tomorrows) had an old El Toro. Charles (Grinder for No Tomorrows) wanted to get into the action, so we decided to use Tony’s little sailboat as a plug, make a mold and pull a few of them.
Friday, October 26, 2007
Back burner and run.
I found a freebee mold at boat school. After looking it over we decided to put the El Toro project on hold and pull a part out if this new mold. Hopefully this new boat would make a sellable little 8 foot fishing/row boat.
And that’s exactly what we did the very next day. Little did we know that this would result in us being kicked out of Tony’s garage. See the Left Coast links for more on this nonsense.
Monday, October 8, 2007
Block sanding.. Uggh!!
The entire boat was rotting. The more we sanded, trying to smooth it, the rougher it got. Time for desperate measures.
Tony and I mixed up about a 1/2 gallon of epoxy with yellow pigment and a little 410 for future sanding fun. Tony mixing with me running a paint roller we coated the entire bottom and sides with a couple coats of liquid plastic.
We blocked down the entire boat bottom only to realize, it needed to be done yet again. We’d used the little rubber sanding blocks and they left hills and valleys. This time it was white pigment, three coats of epoxy, no filler.
The entire boat was block sanded with 36 grit on long blocks. Now that smoothed out some stuff! Block sanding took about 2 weeks or so as a back burner project. Finally it was complete and we were able to start on the top of the boat.
There was a lot of design issues pushed back ‘till this point in the project. So, I’m having sleepless nights dealing with them. Where are the split lines for the mold going to be?
Wednesday, September 12, 2007
Carving and sculpting
Just a little carving and block sanding. One gunnel was rotten on both ends. the other was missing so we attached a new one. We should have replaced both but didn’t know at the time just how much work and tears the rotten one would cause.
West system, using 410 filler, has problems when you try to use it as Bondo. No matter how thick you mix it, it flows. It would go on just perfect. Then, before it would kick off, it would soften and flow away. This caused days of frustration. %$@*&!! We used the 410 ‘cause it was the easiest to sand.
The missing/replaced front and rear corners needed to be built up, filled, shaped and smoothed. The old rotten gunnel needed to be re-sculpted into shape. There was a lot of the nose of the boat missing, that was rebuilt completely with 410 blobs. Ugh! Not to mention random gouges here and there on the hull skin. Sculpting the rotting hulk into an El Toro shape ended up taking weeks.
Thursday, August 9, 2007
Closing up the plug
Very happy with the results from the last night’s work. The boat now has actual corners. This was not just a little “whoops” thing, it was originally missing about a foot of one front corner. We’d rebuilt from the inside and epoxy glassed it in.
Next we attached a 1/8” door skin as a lid over the boat. This was because I wanted to do a mold with an in-turned flange. Also, this would give a good line to work from when re-carving all the rotted trim strips and edges.
In the words of Jason, “It looks like Tony found this in a creek.”
Once the top was glued and screwed down we routed off the edge.
Next a little body filler, smooth everything out and we’d start building the mold. Yeah right!
Wednesday, August 8, 2007 - Guessing at the date here..
Checking out Tony's El Toro.
This isn’t Tony’s El Toro. This isn’t Tony’s garage. This is just some pic I stole off the internet of an old El Toro. Tony’s El Toro was way more thrashed than this one!  Tony got some pix at the time, but there still in his camera. The front and rear corner’s on Tony’s had actually rotted off the boat entirely.
First order of business was to glass some wood to the corners. (Where the corners were missing.) We used the rotting deck as a doner for the wood, It was the same thickness so it matched up nicly for bending.
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Everything you ever wanted to know about the El Toro sailboat.
A little About ~ El Toros.. Hey! Where’s Charles’ head? Charles Tony