Finishing up!

I purchased a 10x17 portable garage at Harbor freight. Two overhead 2x40W T-12 light fixtures is providing light. With a good 3M solvent rated mask it is fine despite the small volume. 

I still had to finish up the bottom. I thickened the bottom shell with a layer of 1.5oz mat and resin that i filled with Poly-Fair from Merton's fiberglass. I let it overlap the keel with about 4" on each side to provide reinforcement when its on the trailer. 

Here is the area where the gunwhale had to be rebuilt after filler and fairing. I did not get it as hollowed out as the original but its not visible unless you are in the water:-) 

The finished bow. This was a lot of pain but it turned out pretty good! 

Masking the waterline. I rolled the bottom paint and the primer so i only used a single strip of tape. After i put one layer of  bottom paint and two coats of primer and topcoat i pulled the tape and taped the very edge of topcoat leaving about 0.020-0.040 of topcoat sticking out that a carefully sanded to a taper before rolling the last layer of bottom paint. I rolled one layer just where the tape had been and had that dry before roling the whole bottom. One full can of Rustoleum was exactly what it took. Next tome i will put on the first layer thin and keep the roller tray with paint in to avoid the "running out of paint stress"

One layer of primer and one bottom coat. I tried the Harbor Freight HVLP sprayer kit but it was useless! A roller gives better finish..

Two layers of rustoleum topcoat. This i used Home Depots $49 Husky 4CFM HVLP spray gun. Worked way better. I only have a hitachi pancake compressor rated 4.9 cfm at 40psi but it worked fine

Pulling the 3M mask tape (the new thin edgeblock type) worked very well. 

Flipped over, wood installed, engine hanging!

Ready for the water. 

Back in the lake!