Feedback: Zip
built by Nathan A. Miller
12/5/03. Received the full size patterns in November 2003. Constructed frames with Quarter-sawn 4/4 White Oak. Can barely see that the aft frame was originally built to have walk-though between front and back cockpit. Later in construction, I decided that this would take too much seating away from the front cockpit and filled in the frame cutout. Here the frames are just propped up for a photo-op.
5/15/04. Made start and go progress through Winter 2003-2004. The workshop is completely unheated so it was difficult to find days that were temperate enough for both woodworking and to allow for the Poxy-Grip to set. By May 2004, the framework was completed and ready to start fairing. Only broke one sheer lamination in the process. Used rags soaked in boiling water to soften the forward part of the sheer and chine while springing in. The chine and sheer are sycamore (I think).
11/25/04. Fairing seemed to take forever, even when assisted by careful work with a power-plane. Side planking and forward part of bottom planking are ¼" Mahogany veneer plywood from Boulter Plywood in Massachusetts (http://boulterplywood.com). I was very impressed with how quickly Boulter processed and shipped my order (something like 1 week from order to arrival in Virginia). The aft part of the bottom is ¼" Fir since it will be painted. I used a power planer and a steel straight edge to prop up one side of the planer to plane the scarf joints with pretty good results. I should have taken more time in setting up the scarf joints on the plywood. The alignment was ok but there are areas where the pressure wasn't as even as it should have been (used a collection of various heavy items over a 2x4 to hold the joints together on the floor). Note the fluorescent paint spots that marked where the frame was screwed to the building jig. Was helpful in finding where to detach the boat after everything was coated in sawdust from construction.
6/11/05. Stained the hull with a combination of ¾ part "Transparent Red Mahogany" and ¼ part "Brown Seal" dyes from W D Lockwood (http://www.wdlockwood.com). Color was a little darker than I wanted so I used half as much Seal Brown on the deck. The hull is covered in 6oz cloth and then covered with 3 coats of West Systems 105/207 epoxy. Temperatures were just above the recommended 60F when applying but I should have waited for warmer weather. I had lots of problems with getting the epoxy too thick and sagging. After much debate on how to flip the boat, I came up with this arrangement of come-alongs and strapping. Note my wife Brooke's hand holding the boat steady. After jacking it up, I thought I had probably should call some friends to help, even though it looked like it would be pretty simple to do the flip. I was most worried about how quickly the boat would turn after it got moving. In a freak circumstance, my wife actually encouraged me to try it with just us and NOT to call any help! Since when does that happen?
6/11/05. The boat was pretty stable going over and didn't go out of control at all. Very easy to do. One problem was that I didn't have quite enough take-up in the come-alongs to get the boat completely over. Here the sheer is against the concrete floor. After a bit of debate, I just took a deep breath, picked up the bow and finished the flip.
6/11/05. All flipped with no problems!