Install Daggerboard Trunk

Draw a centerline in the Cockpit sole. Use the Daggerboard Trunk and trace a rough outline 3/4” from the companionway bulkhead making sure it is on the centerline. Use a jig saw to cut the rough hole with at least a 1/8” gap all around. Add a chamfer to the top edge of the hole. Do not try to make the opening too tight as you will need the extra space to backfill with epoxy and orientate the daggerboard. Once the rough hole is cut, insert the daggerboard trunk into the hole and lightly hold it in place so that it is perpendicular. Draw another outline of the trunk where it comes in contact with the hull bottom panels. Make sure it is on the centerline and plumb. Again use a jig saw to cut the hole with at least a 1/8” gap all around. Add a chamfer to the bottom edge of the hole. Now test fit the trunk making sure that it is on centerline and plumb. There should be some extra section of trunk extending past the holes on either side. When you are satisfied it is correctly orientated, mix up some thickened epoxy and glue the trunk in place. It is good to use a putty knife to force it into the gap. Do not pinch the trunk with wedges, clamps or other means at this stage as you could squeeze the trunk and the daggerboard will no longer fit.

Once the epoxy has cured double check the orientation of the trunk. Slide the daggerboard into the trunk to make sure it still fits well. Once you are satisfied with the fit you can trim the excess parts of the trunk flush to the cockpit sole and the bottom of the boat. Backfill any voids and sweep a generous 1” radius fillet on the seam inside the boat. Carefully laminate 3 layers of 8.8 oz glass over the opening being careful not to get any epoxy drips into the trunk. Once the epoxy has cured you can trim the excess laminate from the trunk opening. (Note that doing some of these steps can be a lot easier once the boat is flipped)

Sand the fillet and bonding surfaces inside the boat to make sure they are smooth. It is very important to prep these surfaces as well as possible as this secondary bond is extremely critical. Clean area with Acetone or Denatured Alchohol. Apply at least 5 layers of 8.8 oz cloth over the fillet, overlapping onto the glass areas at least 3”.