Monthly Archives: July 2008

6/275 Substantial Completion & Off On Vacation

The last three days I have gotten a few things done. I fabricated and epoxied a couple of thimbles to the yard. I finished epoxying the front hatch. I epoxied 1/4 inch ply to the 11 and 13 bulkheads in front of and behind the hatch so that the decking will look continuous when installed.

What’s left:
– Mast
– melt lead into rudder for sinkweight
– cut slot in rudder as a reboarding aid
– epoxy mast step to bottom
– epoxy motor board to transom
– epoxy rudder mounting board to transom
– build tiller
– glass bottom
– epoxy stem after installing U-Bolts which are in transit from Duckworks BBS
– Epoxy and attach keel to bottom after bottom glassed
– Sand and varnish and paint
– Attach all rigging, rudder, leeboard

It’s getting to be a relatively short list! We are leaving on vacation Friday for a couple of weeks. I will be back on August 3rd for a week and hope to get a lot done before I go back to BC to pick up Patty and the boys. As we are going to BC if I can obtain some good lumber out there for the mast I may put it together while I am gone. My buddy Mike, who lives in Duncan would love to do that I am sure….as long as I let him use his chainsaw on the mast at some point in time 😉

Hopefully it will be on the water by the end of August. I don’t want to be learning to sail in September as the lakes are already getting pretty cold by then.

Photos of where things are at right now….

See ya later!!!


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15/269 Transom, Hatch Covers, etc.

The last couple of days I have gotten a fair bit done. I am undecided on whether or not to use the epoxy primer I have or to go with an alkyd or latex primer. I had been planning on starting to prime the inside of the bulkheads Saturday morning but decided to do other things instead while I thought about what type of paint to use.

I have gone over the edges of the deck covers with the 1/4″ round over bit and in the places I can’t reach with the router I have used my trusty handplane and a sanding block. It looks much better with the square edges knocked off.

Saturday morning I grabbed a 2×4 I have had laying around and tried fitting it to the transom. The transom plywood has developed a bit of an inward curve. The 2×4 was also curved so I tried clamping it with the curve outwards and pulling the transom to it. I think it would have left too large a gap that may have been difficult to fill and turned the other way the curves matched nicely and it was an easy clamp job. I cut it approximately to length.

Then, I decided to lower the transom by 3″ so that it has a finished height of about 15″. I marked this out and then used the jigsaw to cut it fairly close. After it was close I clamped a piece of wood to the inside of the transom on the final cut line and used the router with the edge trimming bit to cut to the edge. A bit more work with a wood rasp and the sanding block and things were looking good.

Then, I decided to drill holes for the 3/8″ bolts suggested by Jim Michalak to bolt the transom support posts (Made of 2x4s) to the 2×4 motor board. I had previously picked up 3 1/2″ long bolts which were too short. After drilling the holes I decided to drill some recesses so that the bolts would be usable. Because I had drilled 3/8″ holes I figured that the Forstner bits would be difficult to center and decided to use the large router bit I have that is 1 1/8″ across. Well, it did the job but it ain’t too pretty! I may just fill those holes right in with filleting material before I am done.

That being done I cut the small pieces of wood that go around the outside edge of the wood. I debated doing an inlay but eventually opted for the easier route of cutting the hatch covers and then fitting the wood to the edges with rabbeted joints.

Hunter helped me by turning the saw off and on and actually cut a couple of pieces to length on the table saw with me watching him like a hawk. He was pretty scared and asked to just man the switch. I am glad he has respect for the danger of this machine but it was good for him to give it a try.

By the time the evening ended I had one hatch cover glued and clamped. The other one will have to wait for late tomorrow or Monday as we are going to Iroquois Lake tomorrow to hopefully do a little kayaking and to mow the grass on our lot.


Lastly, just the plywood for the front hatch cover laying in place…

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10/254 Dylan Walker – This Bolt’s For You!

The last couple of days have been busy. I have worked part days and come home to work on the boat.

Wednesday I built the hatch supports…cut them out, fitted them and epoxied them into place. After I had everything covered in goop and several pieces attached I remembered that I had wanted to lay the plywood on the decking without the inside hatch attached yet so that I could trace the opening in the plywood and cut the deck cover out in one piece. The importance of thinking ahead!

I managed to get everything in place while walking around the garage with a piece of wax paper that I had been using to collect squeezeout stuck to my running shoe. Not a pretty sight I wasn’t.

Here are the deck supports, etc…

Today, Thursday, I found a place in town with some stainless fittings and other useful stuff. I bought an anchor, chain and rope and a u-bolt from them. The u-bolt turned out to be too small for what I had planned to use it for but I’ll find something else for it I am sure.

A couple of weeks ago, my young friend Dylan Walker, from Australia, who has already, at the age of 17 I believe, forgotten more about sailing than I will ever know, suggested that I mount a good stout u-bolt in the anchor well to attach the anchor to. Dylan gave me an education on why, and I decided to use a u-bolt I had on hand that I purchased from Duckworks BBS a while ago for this purpose.

I decided to reinforce the bulkhead so I cut a piece of 3/4 inch by 3 inch fir to fit between the existing bulkhead supports and then cut another piece to go over that and be screwed to the bulkhead, sandwiching the first piece between the plywood of bulkhead 1 and the longer piece of fir. All liberally covered with epoxy…the boat will be pulled to the bottom before that will fail. Here is a photo of the back with the U-bolt mounted.

While the epoxy was setting up, I conscripted Hunter and got him to lay in the bulkhead while I laid the 1/4 inch ply on top of it. He then traced around the outside of the hatch opening. I then cut out the opening and spent quite a bit of time with the jigsaw, handplane and sanding block getting the opening large enough to fit over the hatch. When that was done I decided to use the router and the edge trimming bit to cut the outside edges to shape. I popped up the plywood and slid it over to one side. I used a block of wood the same width as each layer of gunwale to kepp the spacing even and placed this block between the hatch and the opening in the plywood. I then clamped down the plywood and used the anchor to keep it from moving while I routed the edges.

A bit more time with the router and I had things looking pretty good.

Then it was time to drill the holes for the U-bolt. This was a bit difficult as I didn’t have much room under the supports previously installed…would have been a bit better if I had thought ahead and done this first!

A couple shot with the deck covers…the back ones have yet to be trimmed to fit but that will be an easy job. You can also see the piece of scrap painted green. I’m not so sure I like it today. Hunter asked me about painting it red so I am considering that. What colour to paint the interior is another question….

Tomorrow I will sand the inside of the bulkheads as much as possible and then on Saturday or Sunday I plan to paint the inside of the bulkheads with primer….BIG STEP!!

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5/244 Front Deck Reinforcements

Before going to work this morning I epoxied two support pieces to the sides of the front compartments about 1/3 of the way from the front. After work I cut the slots for the cross piece and fitted a cross piece. Then, rather than cut the slots I decided to screw/epoxy on a couple of narrow supports for a piece that runs from the crosspiece to the front bulkhead. This is there to keep the pieces from bulkhead 4.5 to the crosspiece from pushing the crosspiece out of shape.

On the way home from work I picked up some primer and alkyd marine enamel from General Paint. I chose a dark green for the main colour of the boat. At the end of the night I painted about a square foot on a piece of scrap. I think it will look pretty good.


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3/239 Hatch, Mast?, Partner

I came home from work a bit early and proceeded to epoxy together the rear hatch supports. It went pretty well.

I also epoxied the last piece of the mast partner. Later in the evening I clamped the partner to the bulkhead and drilled holes through the bulkhead.

I also ripped the 2×10 into 3 strips…the centre about 1 1/2 inches which are cracked and scrap….and two pieces off the sides. Except for a couple of bad knotty spots on one of them I would be in business I think. I’m going to look at scarfing the one with the bad spots and see what I would get. Otherwise I’m going to go back and get another 2×10 or a few 2×4’s or 6’s until I get something worth gluing up.

After consulting with Chuck L. I have decided to construct hatch supports for the front bulkhead similar to the rear one. I’ll add a cross member about 1/3 of the way from the front to the rear and then construct supports similar to the ones just finished for the rear compartment. With any luck I’ll have that well under way by the end of tomorrow.

This photo shows approximately where I will add the cross member. The hatch will have an opening of about 14 inches, the same as the hatch at the rear.

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6/236 Hatches

I slept in a bit this morning but got up to a cool morning on the edge of rain. It was a nice change from the heat. I started out the day by putting a wrap of 3″ tape around the ends of the yard and boom where holes will be drilled to run lines through to tie to the sail.

Then, I went downtown to the office to pick something up and I headed to the north end to buy some more lumber. Picked up some mahogany and some douglas fir and a big old 16′ spruce 2 x 10 that I am going to make a mast from. If it breaks I’ll try something different. $13.99 it cost.

Got home and had lunch. Terry and Chuck came by to check on the progress and sit in the boat …. on the seats. We had a few laughs before they headed off in one of Terry’s fastidiously restored MGs. Dark British racing green…I like that colour a lot and may use it on this boat.

Then, I decided to do the hatches and decking a little different than what Jim suggests in the plans. I am doing them similar to how Chuck L. does his hatches. Quite a while ago Chuck sent me a link to photos of how he builds his hatches and decks and I decided I liked his way better. I think it will be stronger.

So, I started by measuring out from the centre lines on bulkheads 11 and 13, setting the opening and then laying out where to cut into the bulkhead support pieces. My plan was to cut on an angle from the bottom edge up to the edge against the bulkhead plywood at the top. After making several cuts, remove the waste with a chisel. Then, cut matching angles on the support pieces and drop them in. Sort of like a wedged/dovetail joint. The support piece can’t fall through to the bottom.

That went fairly well. Then I cut pieces to fit of 3/4 x 1 1/2 inch mahogany. After they were in place I cut pieces of douglas fir 3/4 x 2 1/2 inches or maybe it was 2 3/4 inches to use to form a box that fits inside the rectangle formed by the bulkheads and support pieces just installed. I rabbeted the joints using several passes on the table saw using the miter guide with the blade set to 5/16″ high. (One of these days I am going to buy a dado blade set.) Some fiddling to get the pieces running fore and aft to fit and things were close enough to utilize the tremendous gap-filling properties of thickened epoxy.

Then, I pulled out a piece of 1/4″ plywood that was too small to cover either of the bulkheads and cut out pieces to fit on either side of the rear hatch. There will also be enough left over for the hatch cover itself. It will be interesting to see if I will be able to use any of the other cutoff pieces for the front decking and hatch cover.

I also epoxied part of the mast partner together. I had been thinking I would epoxy the mast step into place and then align the partner before drilling holes in the bulkhead supports. Now, I think I will line the partner up to the centre as best I can, drill the holes and mount it and then I will determine exactly where the step should be located and epoxy it to the bottom.

Here are some photos…

Some of the crew returned from Yorkton….

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7/230 Seats!

Today I spent a lot of time with the belt sander shaping the rudder and leeboard. I also drilled holes in the rudder and rudder cheek and bolted them together. Not much to say about that but the wind was howling outside, it was hot and the belt sander is noisy. Our poor neighbours are going to be glad to see me loading this boat on a trailer and not working on it anymore.

Then, I hauled the 3/8″ plywood up from the basement and started figuring out how to cut and fit the seats. I measured the widest point and used the jigsaw to cut the first seat roughly to size. It was so windy I didn’t want to try using the table saw as everything cut is fed out the garage door to the driveway. I then laid this piece on top of the bulkheads and gunwales and marked the outline of the bulkheads and hull on the bottom of the sheet.

Started working away with my trusty plane….and working and working. As I proceeded I realized that things at the seat level weren’t consistent with things at the gunwale level. I finally got the seat panel to drop in on top of the support 2×4 and rotated it towards the hull. Lots of work to do. I used a pencil to scribe the outer edge and then took down the high points. After a couple of iterations the gap looked pretty consistent but I had a lot of work to do. I decided to set the table saw fence right next to the blade so that I could take off little more than a saw kerf of width. Tried it. Still had lots extra. After two more tries the piece finally fit into place but I have larger gaps than I would like in places……BUT I have a seat in my boat!!!! I am so excited I just get into it and sit down. Then I lie down on my back and then on my side…I could sleep on it in a pinch but I think the boys will fit perfectly 😉

Got busy on the second seat and in 35 minutes had it done and it fir much better than the first one. I didn’t leave as much extra this time and it took a couple of passes with the table saw and a couple of scribing and planing sessions and I was done.

I grabbed a cushion from an old lounge chair, laid it on the seat, made myself a latte and stretched out and had my coffee. It felt great!

Here are some photos….

Finally….the coin in my mast step…

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