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Rabu, 21 September 2016

You Sure it Will Make it out of the Basement







Before totally committing to building a boat in the basement, one needs some kind of proof its not going to be Noahs ark waiting for the basement to flood to get some use. While the tape measure said it would make it out...I wasnt sure that I wasnt another idiot building a big project that was stuck in the basement. I have to make a slight turn at the top of the stairs to clear the kitchen cabinets, so its not a straight shot out of the top of the stairwell.
My first plan was to temporarily set up the frames, transom, stem and keel and then fashion some temporary plywood sheers and take the clamped together skeleton on a trial run. But my son Bill said maybe a tricked up 4x8 sheet of plywood would suffice. Not wanting to remove frames from my set-up form it sounded like a good idea. So some temporary plywood strips were used to simulate the shape of the shears, traced onto scrap plywood and cut to shape. These were screwed to the stem and breasthook assembly which was screwed/clamped to a 4x8. The stem and various bar clamps were used to simulate full beam width of the boat and depth of the boat. The trial run into the stairwell and out at the top went with no issues. I took some clearance measurements at the tight spots and I have some room for more length, beam, and depth....but not enough to change plans to a bigger boat and start all over!
The kitchen in the background was a major project of a few years back. My son and I built all the cabinets, doors, drawers, etc. Maybe it will be another blog someday.

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Rabu, 24 Agustus 2016

Hang on a Minute I Gotta Drain It

There comes a time when the pressure builds and you just gotta do something that you have put off too long....like putting drain plugs in a boat. The thought of drilling big holes in the transom scared the heck out of me, but I couldnt put it off any longer. After contemplating and procrastinating, I reviewed the cross-section of the transom to determine the lowest point in the transom I could drill a perpendicular hole and not breach the plywood bottom planking. I also looked at photos on this blog to see where I had located screws to hold on the bottom planking near the keel as I did not want to drill into one.













I then decided to bore a guide hole in a 2x6 and clamp it to the inside of the transom and another scrap board to the outside to prevent break-out when I drilled through. The first hole when well, and then I moved to the other side of the keel and located the hole and drilled another pilot hole in the 2x6 in the right location. The pictures show the second hole about to be drilled.








I tried to insert the drain sleeve into the hole from the outside, but it was too snug. I used a rotary drum sander to open it up slightly until the sleeve would ease in. Then I marked the sleeve with a Sharpie to leave it about 1/8" long. I removed the sleeve and a tubing cutter was used to cut it off. The sleeves were filed slightly around the outside to provide some fine scratches to ensure a good bite. Epoxy was mixed and coated the inside of the holes. Then some high density #404 filler added to thicken it up and smeared into the holes. The sleeves were inserted fully from the outside and I rigged up a bolt with large washers in each one to make sure they were held firmly in the hole while the epoxy cured.

The next day, I used a small ball peen hammer and slowly peened the brass sleeve over to provide a flange on the inside of the boat. The drain plugs fit in nicely and its all good.


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Senin, 25 April 2016

Flip It Flip it Good

The time for the flip finally arrived! To have some music to flip by, listen to Devo "Whip It" and think "Flip It". Here are the lyrics I put together for it:

Crack that flip
Give your boat a slip
Step on a tack
Break your flippin back
When your project comes along
You must flip it
Before the dream sits out to long
You must flip it
With someone very strong
You must flip it
Now flip it
Into shape
Top side up
Get straight
Go forward
Move ahead
Try to protect it
Its not too late
To flip it
Flip it good
When the right time comes around
You must flip it
You will never live it down
Unless you flip it
No one gets away
Until they flip it
I say flip it
Flip it good
I say flip it
Flip it good
(Repeat from beginning)













The boat was readied for flipping by drilling 1" holes in the box that bow sat on and inserting a pipe clamp with a turnbuckle inserted around the pipe to provide a pivot point. I then rigged that up to a come-along to lift the bow. The plan was to rotate the boat like on a spit. The rear of the boat was place on a salvaged oak bannister rail and jack stands. A rope was also suspended from the ceiling joists as support during the flip.
The forms were removed from underneath the boat, the cradle put in place and with Ted and Roger doing the heavy lifting, we began the flip.
























The oak support was removed and the rope and cradle used to provide a rest at half flip.
The boat now rests on the cradle and a new phase of construction is about to begin!
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Sabtu, 26 Maret 2016

Faking It

In order to determine my plan for the deck planking appearance, I made up some sample boards from the scrap cut offs. I did one set in natural colors on one board. On another longer piece of plywood, I made two sample sets, one with the perimeter and king plank dyed a dark brown and another with perimeter and king plank in a vintage cherry redish dye. I put on a couple coats of epoxy and after a review with my aesthetic advisor, we agreed that the reddish dye was more interesting and seemed to bring out the grain better than the dark brown. The all natural was too much the same. To get a preview of the look of the boat, I set the selected sample on the bow and propped up a mirror behind it to give the appearance of the front of the boat. With the choice made, it was back to getting the decking ready for staining (using a water based dye product).

The first thing to do was plugging the screws for the perimeter planking and king planks. The steel screws used during glue-up were removed, holes bored deeper, silicon bronze screws installed and then wood plugs epoxied in. Plugs were made from cutoffs from the boards used in each place. After setting the plugs were cut flush and sanded.

Then I worked on the outer perimeter, getting the plywood subdeck and planking layer flush to the sides with a vertical edge about 3/4" high. This edge will allow enough surface for a 1/4" radius on the top edge and then a 1/2" stainless steel rubstrip. I had to do some epoxy fill-in at the aft end of the boat where I had previously over cut the plywood due to the tumblehome of the rear sides of the boat. The edge lays over slightly as it approaches the transom so the rub strip will twist a bit towards the transom.

The next order of business was sanding. I took my small belt sander to the whole deck and sanded down any high spots along the king plank edges and over the whole boat to fix quite a few places where the grain was running upwards causing some surface tearout. Then it was a progression with the random orbital sander through 80, 100, 120 and 150 grit paper. A rather small paragraph to explain a whole day of tedious work.







I decided to make a thin molding about 3/16" thick and 3/4" wide to go around the inside of the cockpit and motor well areas to cap the planking boards ends and edges. While simple in concept, it is a bit more involved to fit tight and get around the radiused corners. I made a couple of glue-up jigs to create the molding in the corners. I traced the radius on a piece of plywood, cut it out on the bandsaw, and screwed it down to a scrap board. On the table saw from the planking scraps, I cut about 8" long strips about 0.060" thick, ran hot water over a piece and then formed it into the corner on the boat, taped it in place and let it dry. Then laminated a couple of pieces at a time in the jig using water proof Titebond glue. After a while I had 4 corner moldings that almost fit. The molding is in seven pieces around each opening. The picture shows the epoxy and clamping of the side pieces and a center piece. Then the corners and remaining pieces. Lets hope it all looks good in the end.









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