Thread: David Gomm - New OZ PDRacer Lug Rig Variant under construction in Perth WA

Hi Woodeneye,

I was just making the pasted in material the same size as the default forum font, as using a larger font is possibly getting close to bending, if not breaking the forum recommendations / rules ( and just takes up extra space needlessly ).

Hi everyone,

Now that I have this support boot on my foot ( instead of the cast ), which enables me to stand or limp with full weight on my foot for short periods at least ( bone has completely healed - have to wear the support boot for 6 weeks to let the muscles get back their former strength ), I have made a start on repairing the worst rusty area of my car ( all the rest are fairly minor ), and have driven it to a doctors appointment and shopping today.

Next week I will definitely be doing some more work on the car top rack / loading ramps, and launching trolley, I am not sure how many hours I can do yet, but I am certainly mobile enough to do some work at least now.

I will give regular updates next week on progress so far.

I finally got myself an aluminium ladder, the local "Mitre 10" store is closing down, so at their closing down sale I got myself a new 6/10 step/extension ladder ( 125kg load rating ) for just $84. It was the last ladder in stock, just the size I wanted, how lucky could I have been.

After having the accident, that broke my foot, on a neigbours old 6/10 step/extension steel tube ladder, I thought this was the perfect time to get myself a decent ladder, so it won't happen again.

At least I will feel more safe when using this brand new one, rather than using my old 7/12 step/extension one ( also a steel tube type - but heavier duty, and in better condition than the one that broke ).

Hi everyone,

I have now treated and patched the worst rust spots on my car, juat need to sand back and prepair for repainting, but this is now not urgent.

I have started working on finishing construction of my car top rack/ramp system for the PDRacer, now we have some cooler weather ! ( just 0.2 mm rainfall all summer - the driest on record for Perth - and also the second hottest on record ! ), the last week got to almost 43, and averaged about 37 degrees Celcius - overnight minimum was up to 32, and averaged about 28 degrees Celcius ), which didn't help my depression any either, but I am doing well now.

I can now walk without crutches ( just the Cam Boot for support untill the muscles heal - It can be easily removed when not putting weight on it ! ).

Tottering around again I see. Glad to see you're doing well ... but you will have to find a less painful way of meeting nurses.

Looking forward to seeing your roof loader in action.

Richard

Hi Everyone,

I have just completed filling the temporary screw holes in all 4 I-Beams ( 2 for ramps + 2 for roof rack ), I just need to add the reinforcing pads to the roof rack sections ( to allow the mounting bolt holes to be drilled vertically through the centre of the I-Beams ), and add the 2 hinge sections to each side of 1 end of each ramp section, ( hinged by a single removable bolt each ), before filleting the joins in the I-Beams to complete the construction.

I have also just filleted the sides of my hull bottom runners / hull bottom reinforcements, more to fill in any gaps between the hull with the fibreglass sheathing on the hull bottom runners / hull bottom reinforcements than anything else, when dry the hull is now completely ready for sanding ( inside and outside ), prior to the final resin coat being applied.

To give you an Idea of how strong the roof rack I-Beams are, I accidentally backed over 1 with my '84 Ford Telstar ( 1 end was supported about an inch off the ground - the other end had fallen on to the carport floor beside the wooden block that it was supposed to be supported on ), the end result was just a split in the timber about 1 1/2 feet long of the upper piece ( 10mm thick ), on 1 side of the main section of the I-Beam ( made of 3 pieces ), which I have since glued back together ( it looks as good as new ). They had only been roughly glued together - no fillets or filling of temporary screw holes ( the screws had all been removed several days earlier ).

My foot has recovered almost to the stage where I can walk on it without limping at all, and with almost no pain now too.

Hi Everyone,

I just finished off the extra pieces, and glued and filleted them to the various I-Beam sections, for the ramps, and the roof rack sections today.

I just need to fillet the joins in the I-Beam sections, and drill the mounting holes ( that simply allow the roof beams to be 'clamped' on to existing carry bars etc. ), before sanding them back to complete the basic construction ( this may be completed in as little as a week and a half ).

When I have also sanded back the trolley as well ( 2 - 3 days additional work ), I will post pictures ( free plans to follow later ), so anyone who needs simple, single handed launch/recovery and transport/storage capability, can make them, or something similar for their specific boat(s) if needed.

Sounds great David.

Looking forward to seeing the finished product.

MIK

Hi Everyone,

I have just completed the filleting and filling of the temporary screw holes for the ramps and roof beams, it took 4 hours non stop to finish, I am very tired now, but at lest the hard part is over.

Still to complete:

Sanding should be done on Friday or Saturday, with mounting holes drilled and test fitting done next Monday, then the final sanding can be completed on the hand trolley by the end of next week.

I should be able to photograph everything then ( as the ramps and roof beams, and the hand trolley will just need a coat of resin and painting, before applying the seat belt webbing to all surfaces that contact the PDRacer to complete them ), as they will be structurally complete by then.

Michael, I will be glad to see these items finished too, because then I need to get back to work on my PDRacer, as the hull still needs to be sanded back ( inside and out ), before applying the final resin coat, and painting it.

At this time I can get the HIN fitted to the hull ( the painting and application of seat belt material for the ramps and roof beams, and the hand trolley will need to be completed first ), and finish off making the mast, shaping the foils, and finishing the rudderbox, and tiller, the PDRacer will finally be finished then, and I can just enjoy sailing it.

Hi Everyone,

I have managed to sand both roof rack beams ( except the recessed surfaces if the I- Beam sections ), and mounting blocks, I have drilled holes for the mounting bolts, and with some cut-outs ( in the mounting blocks ) to give clearance of the carry bar mounting brackets, I have successfully test mounted the first one.

I have pilot holes drilled for the second roof rack beam, I will finish test mounting it on Monday, and complete the sanding of the recessed sections of both I-Beam sections on Tuesday.

Hopefully I will give the same treatment to the ramp sections, and test mount them by no later than Thursday ( while we have a week of cooler weather - much better than the recent 41 degree day yesterday, or the 39, and 38 degree days preceding it ).

Hi Everyone,

I surprised myself today, I spent 5.5 hours sanding with my drill mounted disc sander, and finished all of the major sanding ( minus the recessed portions of I-Beam sections and a few fiddly bits ), on the roof mounted racks, their mounts ( now aerodynamically shaped as well ), the ramp sections, and the trolley sections as well.

I have even test fitted the racks to the roof carry bars ( on top of the car ), and the ramps to the racks, all work very well.

Tommorrow I will have a much needed break, before sanding back the recessed I-Beam sections and fiddly bits on Wednesday ( exact method still to be determined, hopefully I can just get away with using mounted stones to smooth most of it ).

Hi Everyone,

Once again my health is letting me down, this time due to a 'Sinus Infection' ( I get 'Chronic Sinusitis' all year round, with about 4 'Infections' of the blockage a year - I have had extensive allergy testing - covering at least 50 of the most common allergens - apparently I am allergic to something other than any of these ).

I saw the Doctor Yesterday afternoon, he promptly put me on a 10 day course of 'Anti - Biotics', this usually does the trick, but sometimes not with the first 'Anti - Biotic' tried, so it could be a week or more before I can really get back to work on the rooftop racks, ramps, and trolley, or the PDRacer in general.

I had a fever of 38.2 degrees Celsius ( 100.2 degrees Fahrenheit ), last night, and just could not get any sleep.

Hopefully everything is OK with everyone else on the forum.

Hi Everyone,

Although I have not yet done the sanding on the tricky bits ( inside of I-Beams etc. ), I am still recovering from my Sinus Infection, and now plan to just take some photos of the car top racks/ramps, the launch/retrieving trolley, and the PDRacer ( still needs another resin coat inside and out, before painting ), being loaded onto the top of the car, so you can see how the system works.

I will take the photos in a few days, and post them here, and on my website, after that I will be getting the PDRacer hull ready for painting.

Hi Everyone,

Here at last are the promised pictures of the One Person Car Top Racks and Loading Ramps, the Launching and Retrieving Trolley, and putting the PDRacer onto the top of my car, this was relatively simple to do all by myself.

I haven't yet sanded back the recessed sections of the I-Beams or other tricky areas of the Car Top Racks, Loading Ramps, or the Trolley, I will be coating all areas of the Car Top Racks, Ramps, and Trolley, that contact with the PDRacer with Seat Belt Webbing ( usinc contact adhesive ), and the PDRacer still needs to be sanded back, before the last coat of resin gets applied.

I feel the need to make up some removable support wedges to sit between the PDRacer and the Car Top Rack, above where the Car Top Racks Clamp To the Carry Bars, this is to stop the ends of the Racks from bending down, and to make firm strapping down of the PDRacer possible.

I intend to get back to finishing the resin coating, and sanding the PDRacer, prior to painting it, next, finishing off the Car Top Racks, Ramps, and Trolley can be done while painting my PDRacer, now that I have demonstrated how well they work.

I will finish drawing up the free plans for the Car Top Racks, Ramps, and Trolley over the next few weeks ( these will be done with a CAD program that I am familliar with ).


Step 1. Trolley awaiting the PDRacer to be loaded onto it - Note: the draw bar is removable from the main Trolley section,so that after setting up the PDRacer and putting it in the water, I can place both sections of the Trolley in the back of the car while I go sailing.


Step 2. PDRacer loaded onto the Trolley, positioned at the foot of the ramps, ready to be flipped over upside down onto the loading ramps.


The Car Top Racks and Loading Ramps in position, ready for car topping the PDRacer and the Trolley.


Step 3. PDRacer and Trolley positioned upside down on the Loading Ramps, just needs a good shove to slide them up onto the Car Top Racks.


Step 4. PDRacer and Trolley in place on the Car Top Racks - the Loading Ramps have been stowed on the outside of each Car Top Rack - The Loading Ramps and PDRacer just need to be tyed down securely for transport - the Mast, Boom, Yard, and Sail, can be tied down on top of the Trolley safely.


This is a close up showing how the Clamp Type Mountings attach to the Carry Bars - they will work with any type without the need for making any holes in your Carry Bars - if coated with Seat Belt Webbing they will not even scratch expensive ROLA types.


This is a close up of the Loading Ramp Hinged Mountings - to attach the bolt simply passes through a hole in the rear of the Car Top Rack I-Beam, with each side of the Ramp Fork section on either side.