tag:blogger.com,1999:blog-22666434195466940692024-02-07T11:23:23.275-08:00"Donkey Rider" The adventure of a first-time boat builder!Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.comBlogger18125tag:blogger.com,1999:blog-2266643419546694069.post-85919074726713070272014-03-01T18:44:00.000-08:002014-03-01T18:45:08.200-08:00A February sail on "The Donkey"<div style="text-align: justify;">
Well...it has been a while, hasn't it? We moved about a year ago and as a result, I have been pretty busy with house stuff, and setting up my new shop (YES!!!) so although I have been sailing, the blog has been pretty stagnant. Actually, seeing as how the boat is essentially done, I won't have much reason to continue to update this blog, other than for the continuing observations of learning how the Duckpunt sails, and making the resulting commentary as I see fit. Continuing forward, I will be putting most future updates into my more general purpose page- <a href="http://thethingsrustydoes.blogspot.com/" target="_blank">"The Things I Do"</a>. I am going to do another boat build soon, so if you have enjoyed this page, please subscribe to that one so you will stay updated with all things Rusty!</div>
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Back to Duckpunts. I took "The Donkey" out the on Friday for a sail on Greenlake, which since moving is only a block and a half from my house. This is so amazing because I can simply put the punt on a cart and roll it right down to the lake for a sail, and never have to deal with grunting the thing onto my car, and driving to a put-in. Greenlake is a beautiful little lake situated just north of Seattle, and is a charming sailing location. I feel so lucky to live here!</div>
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While thoroughly enjoying it, I am still struggling a bit with truly mastering the Duckpunt. Part of this stems from not sailing it often enough to really build a skill set. I also screw up something in the rigging nearly every time I take it out, which is embarrassing to admit since it is only an Opti rig, and does not get much simpler. Still, I manage to mis-rig something almost every outing! I also sail so conservative that I don't ever realize the hull shape's true potential. The punt must be sailed well heeled over to dig the chine in, and I am just not confident doing that when it is cold out, and I am <b>terrified</b> of the water. More practice is needed, although I am still having a blast, whether sailing the boat as good as I could be or not. It will be a long time indeed (if ever) until I am as good at sailing this boat as the <a href="http://youtu.be/rYz4ahHGIuU" target="_blank">Duckpunting chaps in Mersea</a>. They are amazing!</div>
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I was able to film a bit on my outing, and I hope you enjoy watching the video. I hope to continue filming my punting trips, so if nothing else this blog can serve as a video dump. Click on the link below, sit back, relax, and enjoy!</div>
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<a href="https://vimeo.com/87949747" target="_blank">Video of February Duckpunt sailing on Greenlake</a></div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-78240984658750883502013-01-20T19:15:00.002-08:002013-09-08T23:59:02.328-07:00SUCCESS!!!<div class="separator" style="clear: both; text-align: center;">
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<b>"The Donkey"</b> has its maiden voyage!</div>
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We finally had a weather window with sun, light breeze, and warm (for January in Seattle) temps in the upper 40's, so I decided it was an auspicious day to finally put the Punt in the water and see if it floated. Of course the first hurdle was trying to get the beast on top of my car! Funny as it sounds, the entire time I was building the boat I had no idea if I could get it on top of my car or if I was going to have to buy a trailer to haul it (which I most certainly did NOT want to do.) Although built with lighter-weight building techniques than the traditional West Mersea boats, this boat is still MUCH heavier than the light weight versions put together by <a href="http://www.keepturningleft.co.uk/category/duck-punt-films/" target="_blank">Dylan Winter</a>, or <a href="http://duckpunt.wordpress.com/" target="_blank">Stan Richardson</a>, so to say I was worried was no exaggeration, particularly after trying to move the boat around during the build. Stubborn, just like its namesake!</div>
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Well, I found that it WAS doable, albeit with a lot of muscle and swearing. I eventually found that I could swing one end up onto the trunk of my work truck (actually, my Kia Spectra) and slide it up onto the Yakima rack without too much trouble. Not easy, but I got it up there, and taking it down with gravity was going to be <b>much</b> easier. Whew!</div>
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It became very apparent at this point that my paint job left a lot to be desired, and I left a lot of paint everywhere the boat touched. Well, I won't have to worry about dragging it across the beach now! I still think I should just strip the paint and take it to an auto body shop and have them spray the damn thing. Ugly little Punt...</div>
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It was pretty damn exciting putting that boat in the water! As I first pushed off, the boat just went! I could tell that it was going to move through the water pretty easily and be an efficient design, as a lot of hard-chine boats are, in the right conditions. But once I got going...I could <b>not</b> make the damn thing do what I wanted it to! I wanted it to go left, it went right. I wanted to go upwind, it fell off. I thought, "What the hell, this thing sucks!!!" Of course, I was making every mistake that was possible to make and it wasn't the boat's fault at all, I just had to figure out how to sail it. This boat is completely different from any boat I have ever sailed, and I <b>love</b> that about it! </div>
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First, balance is EVERYTHING. I was sitting way too far back and once I moved forward, the boat was able to come up on the wind with no problem. The Opti sail is totally new to me too and handles differently than a Marconi (triangular) sail, and that took some getting used to as well. Still, it is a wonderful sail once you understand how to trim it. It wasn't until I got home that I realized I had rigged it wrong and had inadequate luff tension (the front edge of the sail,) so I am anxious to get the boat back on the water and see how the correct rigging improves the sailing performance. </div>
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Well, that brings us to the funnest part of this blog so far...the maiden voyage videos! Never having used one before, or even really testing this one, I mounted a GoPro camera to the bow, pressed "record," and hoped for the best. I admit, they are not the most exciting videos ever made, and I am no brilliant film maker like <a href="http://www.keepturningleft.co.uk/about/" target="_blank">Dylan Winter</a>, but they are something I am fond and even a little proud of. There are two tacks showing the boat speed in around 3 to 5 knots of wind. It was a beautiful day and a happy ending to a long process. I hope you enjoy them!</div>
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<span style="text-align: justify;">Thanks for following along as I muddled my way through this boat build! It was a lot of fun to do, and the blog was a lot of fun to share with you. Who knows, maybe another boat build will be in my future...</span></div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com7tag:blogger.com,1999:blog-2266643419546694069.post-22327324920836441662012-12-11T01:12:00.000-08:002012-12-11T01:19:54.700-08:00The end is in sight!<div style="text-align: center;">
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What a looong process. The boat that I thought I could crank out in a conservative six weeks (and the design which <a href="http://www.google.com/url?sa=t&rct=j&q=dylan%20winter%20duck%20punt&source=web&cd=3&cad=rja&ved=0CE8QtwIwAg&url=http%3A%2F%2Fwww.youtube.com%2Fwatch%3Fv%3DdXvN5C_DsrQ&ei=7OzGUK2DDqPOiwKmwYGYDA&usg=AFQjCNGng_JUGwEUZ_0vIkCZXtETNL0yIw&bvm=bv.1354675689,d.cGE" target="_blank">Dylan Winter</a> built in only ONE week) has taken me over six months! Granted, as the name of the blog clearly states, I <i>am</i> (or <i>was</i>) a first time boat builder, so perhaps my original assessment of my ability to build a boat was a little optimistic.<br />
There were challenges associated with having to build it out in our courtyard, with all the schlepping of tools back and forth, and no ready electricity. There was the stubbornness of having to do the entire thing by myself, without any help from others. There was the frustration of only having a few hours a week to work on the boat between my job, music, relationship, and all the other things that fill up your time while living life. There was the challenge of trying to figure out what all those lines were on the 8x10 sheets of paper that were all I had for a building plan. There was scheduling when I could borrow a truck to pick up the materials that I needed (and the ones I needed <b>again</b> when I made some dumb mistake!) Oh, and speaking of...all the mistakes, those wonderful learning opportunities which came up again and again. Sigh. Paint masks a myriad of things, thank goodness I wasn't ever planning on varnishing! </div>
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Well, it is certainly not a show piece, and it will never win any awards, but it is good enough for a first boat build, and I am happy enough with it, if not exactly satisfied with how it came out. I have to keep reminding myself that I built it as knock-around boat, and it is going to get pretty beat up in short order, and a Duck Punt is a Duck Punt, not a swan! I still need to put some additional coats of paint on the interior but I am going to wait until spring when it warms up again and call this thing done for now! Enjoy the finished pics and expect my next post to be from the water!</div>
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The stern brass skid plates. I don't know why I used two, I think it looks cool though. I should have used countersunk screws but I was out. I'll fix it later.</div>
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Here is the bow skid plate. It doesn't fit perfect, but it fits as good as I could get it considering I had to do the bends at work away from the boat.</div>
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A boat that is ready to sail! View from the stern quarter.</div>
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And from the starboard bow.</div>
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And from the port bow.</div>
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I still have no idea if I can even get this thing on top of my car. It is really heavy! Maiden voyage will be dependent on decent weather and getting over a little illness I am struggling with. I am a little nervous about sailing it, to be honest. The Duck Punt sails completely different from any other boat I have owned so I have a lot to learn about how it is handled. I hope it is a fun process! Stay tuned!</div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com3tag:blogger.com,1999:blog-2266643419546694069.post-63138008616868386862012-11-15T22:21:00.000-08:002012-11-15T22:21:39.810-08:00"Smooooth strokes, up and down....<div style="text-align: center;">
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<a href="http://www.metacafe.com/watch/an-AyGv47b2bhnt2/the_money_pit_1986_maxs_confession_part_2/" target="_blank">...paint, don't tickle!"</a></div>
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I have finally found something I hate more than epoxy! I hate primer, priming, paint, painting, and anything to do with a brush, roller, or paint can. Well, there is nothing for it, so I started rolling, and brushing, and cursing. The next time I build a boat I am rolling it right into an auto body shop and having them spray the whole damn thing. I can't believe I didn't think of it before! Genius! </div>
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Still, it is nice to get rid of the hideous plywood/epoxy combo finish and turn the boat sorta white. Unfortunately, it is getting quite cold and although the primer is drying, it is not really curing. I had the Punt upside down while priming the bottom, and after a week of sitting curing the primer still scraped off the hull when I rolled the boat to primer the interior. Either the primer was not fully cured, or it did not fully bond to the epoxy. Either way, I came to the conclusion that I don't really care. I am just going to slap white onto this thing until it's covered, and go sailing! This is not a show boat, as I have said before, and I built it to use, not look pretty. It is going to get scratched up, knocked around, banged by rocks and scraped by beaching. I am going to be patching and painting it anyway, so why should I care if it looks perfect from the start? Unlike having a new car, I am really looking forward to that first legitimate scratch so I can claim it as a real boat! Maybe the paint will finally cure next year...</div>
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A couple of views so far, with only one coat of primer-</div>
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I guess the next post will be the Punt fully painted. I still have to do some rigging and build that interior plank so we have a few more posts to go before we close this chapter as first time boat builder. Stay tuned!</div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-66623021918423420902012-11-05T03:18:00.000-08:002012-11-15T22:23:14.291-08:00A milestone!<div class="separator" style="clear: both; text-align: justify;">
I had thought for a while that I would never say these words, but...I have finished the "construction" phase of the Duck Punt! With the exception of the rigging and the seating, I installed the last piece of wood this week, and began the arduous process of sanding in preparation for painting. I am so excited to be nearing completion and being so close to having a new boat!</div>
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I had a fairly long list of projects left to do last time I posted, so let's take a look at what has been done.</div>
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I finally tackled the sheer. It sucks. For whatever reason, the sides are not perfectly symmetrical. Perhaps it was building on uneven ground, on rickety sawhorses that moved whenever I touched the boat; perhaps my measurements were a little off while measuring in the dark; but whatever caused it there is a little bit of asymmetry to the sheer, and a bit of twist in the hull. Nothing that will affect performance, but it will be there to remind me that even the simplest of boats are tricky to build perfectly. It's not bad enough to bother me though, and I know the next boat will be better! Once I was done with the sheer I took a router and rounded it over which you can see in the following photos. It gives the boat a much more finished look.</div>
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Below you can see the bow which had that former wicked sharp entry. Unfortunately, I need a flat surface to attach a brass rubstrake to so this is the current bow profile. The Punt is a thin water boat and I expect it is going to be running into things from time to time so the brass rubstrake is an important piece!</div>
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In the photo below you can also see that I cleaned up the epoxy mess that I had after sheathing the bottom. Another valuable lesson learned...trim your glass to size before installing it and clean up your epoxy before it cures! Grinding off all the excess was a major workout and such a waste of time when I could have just prepped it better. Well, that's what I get for being lazy. This boat is not going to have a mirror finish, that's for sure! I just scraped and sanded the sides and bottom enough to take off the high spots. I think it is going to look kinda rough but we'll see once there is primer and paint on it. Poor, ugly, little punt...</div>
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I drilled out the thole pin holes, and since I knew I was going to be spending a lot of time leaning against the planks I gave them a healthy round-over as well.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjqLAYMR8K2aNAh9lY7Lkjq9pf88PA9w_3XaworaijoWhbu7fo49Eu2dptrf_aZBzdaKZPWWY4ja3U9pz3Jdyas0w4rGCMHcFVS__XRpo7iUXfpumHvf4xbVxElxYpMkjoO_yoBncYxOg/s1600/IMG_5338.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjqLAYMR8K2aNAh9lY7Lkjq9pf88PA9w_3XaworaijoWhbu7fo49Eu2dptrf_aZBzdaKZPWWY4ja3U9pz3Jdyas0w4rGCMHcFVS__XRpo7iUXfpumHvf4xbVxElxYpMkjoO_yoBncYxOg/s320/IMG_5338.JPG" width="320" /></a><br />
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I decided to deck over part of the bow and stern. This will add rigidity to the hull and give me a place to tie in floatation if I decide to add some. </div>
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Another view of the bow deck...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimtv4oEMFFcL3kxA-8yaSwDe3Ca05xyYvP73u3nDULm86OzzKG4bnbsQ7crSmAOWxJ311hEFX0fh2pZ6kPJjOOW5S0b3R5NZ_Xc31e2xOMrCJ-hGOMl4hTah3b8Y_Y3jxk2wTK0J21yoQ/s1600/IMG_5333.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimtv4oEMFFcL3kxA-8yaSwDe3Ca05xyYvP73u3nDULm86OzzKG4bnbsQ7crSmAOWxJ311hEFX0fh2pZ6kPJjOOW5S0b3R5NZ_Xc31e2xOMrCJ-hGOMl4hTah3b8Y_Y3jxk2wTK0J21yoQ/s320/IMG_5333.JPG" width="320" /></a></div>
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...and the stern deck.</div>
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You can also see in the photo below that I finally rounded over the frames.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCGVXuw7kgQU23dlEUytI1DNTkJNwwY3x1LZK-iksGLPbox33Ukj0gU1fwmM22z1Zhi2eMrCp3YC2YJbnuytTnN1PLoKZhAOopC7PKi_QuZXY3jzhcLIPLZ4SFByTJ5-HVLf90q1MWJPE/s1600/IMG_5336.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCGVXuw7kgQU23dlEUytI1DNTkJNwwY3x1LZK-iksGLPbox33Ukj0gU1fwmM22z1Zhi2eMrCp3YC2YJbnuytTnN1PLoKZhAOopC7PKi_QuZXY3jzhcLIPLZ4SFByTJ5-HVLf90q1MWJPE/s320/IMG_5336.JPG" width="320" /></a></div>
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It's the return of "Big Heavy Rock!" </div>
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I finally got the punt on the ground and leveled it out so I could put the mast in and figure out the position of the mast step. I used a laser lever to get the mast plumb and marked the position of the mast step and epoxied it down. BHR was there to hold it fast while the epoxy cured. There was no information on the plans for mast rake or placement so after scrutinizing the youtube videos I came up with a highly scientific method and guessed. Probably good enough... </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMMeJQ0CzsYTGUKFCmJjPc2v2FmaZdg9b0ksN77hE8L2ARdmgAldno6yrSNPb23fwNtjqApv7mlIFNbLfklSprMwo-IoLrKiQxqqiDFnTMiYwSOjMUhvhoqGyzn2GwaJuBo-4raovevkI/s1600/IMG_5335.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMMeJQ0CzsYTGUKFCmJjPc2v2FmaZdg9b0ksN77hE8L2ARdmgAldno6yrSNPb23fwNtjqApv7mlIFNbLfklSprMwo-IoLrKiQxqqiDFnTMiYwSOjMUhvhoqGyzn2GwaJuBo-4raovevkI/s320/IMG_5335.JPG" width="320" /></a></div>
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A complete(ish) boat!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvPDtNBbNlA04O3TWF_xo5eeAfjFIlZwf9YYzfCaWvd12ReW7WY9cy8z1GHLlWDtO3Slb3YEsELVkOYCt7uXgkJCcUmydMJ8HMTFqcBCrhX7GPEiEQKj8MJg0CmpCXgKZIjNJ6CF7gT64/s1600/IMG_5341.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvPDtNBbNlA04O3TWF_xo5eeAfjFIlZwf9YYzfCaWvd12ReW7WY9cy8z1GHLlWDtO3Slb3YEsELVkOYCt7uXgkJCcUmydMJ8HMTFqcBCrhX7GPEiEQKj8MJg0CmpCXgKZIjNJ6CF7gT64/s320/IMG_5341.JPG" width="320" /></a></div>
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Another view...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtmY8fS-IhEKyxymxT51QTfVnlF9dTxaxrmqt3_Vzr0piwwxH8zh8RzO0r-b8ebC2cAA6k_CaQaLTsqbyVtFBTsJrH-Pvk439ZLC7TlzcnvAOzxrgHAngunWI0epi5UomJVMxmrAlaJLw/s1600/IMG_5340.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtmY8fS-IhEKyxymxT51QTfVnlF9dTxaxrmqt3_Vzr0piwwxH8zh8RzO0r-b8ebC2cAA6k_CaQaLTsqbyVtFBTsJrH-Pvk439ZLC7TlzcnvAOzxrgHAngunWI0epi5UomJVMxmrAlaJLw/s320/IMG_5340.JPG" width="320" /></a></div>
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So now the main thing I have left to do is sanding. I am not going to go crazy with it because this is a boat that is going to get knocked around a lot, and I am going to be doing a lot of patching and painting anyway. I like the ten foot rule. If it looks good from ten feet, it looks good enough! I also need to figure out the interior deck that you sit on while sailing the Punt. I have seen people use slats, or a central plank, but the Mersea guys use a single piece of plywood and I think that is probably what I am going to end up doing. I think it will be more comfortable, and keep my gear drier too. I also want to rig a back rest of some kind so I am working on some ideas there too. The next post will have this boat painted so stay tuned, we are almost done!!!!</div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-64959677854094124452012-10-14T00:59:00.000-07:002012-11-05T03:25:28.013-08:00Runs, drips, and errors...lots of them!!!<div class="separator" style="clear: both; text-align: center;">
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This will be a short post. (Keep the applause down, thank you.)</div>
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The weather has made a major change here in Seattle, and summer is over. The rain has begun, the temperature has dropped, and the sense of desperation in the Duck Punt build has become tangible. Once the temperature drops below the 50s, the chance of the epoxy fully curing decreases significantly. Well, I still had a lot to do, so I put in some time in the last decent weather window I had, and started sheathing the bottom in fiberglass. </div>
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I had vacillated back and forth throughout the build, trying to decide whether I was going to sheath the bottom, or just leave it raw plywood and paint it. My reasons for leaving it raw were threefold. One being cost; I knew I would have to buy additional epoxy resin and fiberglass cloth, and I wasn't sure I would want to spend the additional money. Well, I needed to buy more epoxy to finish the build so I certainly had enough to do the bottom, and the glass cloth is not that expensive, so that was a fairly minor point. Two being weight; I really want to keep the Punt car-toppable, and adding glass and resin was going to increase the weight of the boat a fair amount. Unfortunately, by using the heavier Hydratek plywood, and generally "overbuilding" as I have gone along, the boat has turned out to be MUCH heavier than I was expecting. I don't know if it would have been car-toppable anyway, but the adding of glass and resin to the bottom was not significant enough to be a factor. And three being time; I am just damn tired of <i>building</i> a boat, and I want to get my ass out there and <i>use</i> it! (<a href="http://www.youtube.com/watch?v=dXvN5C_DsrQ" target="_blank">Dylan Winter</a> built one of these in 7 days?!) I knew that sheathing the bottom was going to add a couple of weeks to the overall project, and with winter approaching I was worried that I wouldn't have time to finish before the weather prevented me from doing so. This is the disadvantage of building outside when any smart boat builder has their own shop. That being said, I am reminded of what a friend told me when I was lamenting having to build my boat outside. He said, "The vikings didn't have heated shops with lights and coffee makers, they built their boats on the beach!" So...let's get back to work! Sheathing it is!</div>
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First, I layed the cloth out and smoothed it over the bottom of the boat, taking out any wrinkles and making sure it was nice and flat and under a little tension so it wouldn't bunch up as I wet it out with the epoxy. Then I trimmed the sides a little long knowing I was going to be grinding and fairing it smooth later. I used a little blue tape to keep it from moving as I was working with it.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmfPd9r5L8e2N5k_2JuhaBbmCY1TxoF0QSUpGuTkA-fhHhLDpUGOjDZFYYkmqOTYEvhw0BBiGE8vE96U_zr7e-Op19dodcPomrh3KezzQInpEH6baA64peVN8NTeScw_X5oHn2at1W6hQ/s1600/1.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmfPd9r5L8e2N5k_2JuhaBbmCY1TxoF0QSUpGuTkA-fhHhLDpUGOjDZFYYkmqOTYEvhw0BBiGE8vE96U_zr7e-Op19dodcPomrh3KezzQInpEH6baA64peVN8NTeScw_X5oHn2at1W6hQ/s320/1.JPG" width="320" /></a></div>
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The first coat of epoxy wets out the glass and adheres it to the plywood. It's interesting how the glass becomes translucent when wet. The epoxy is applied with a flat plastic scraper which keeps the resin from being too thick and makes it a consistent saturation into the fiberglass cloth.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZ3a1qAcMD9wU3OZSag7WJkpNt8HoMBBS_x3QI1in9MbPAorYowC_IMlq7iPcykaCpejfQLXYWsCuthQupHIlVRBEmDsiJAIkyA6jpp9sCs3J-5b8dnWFPEVDiQCvZTirMShtzKPoBwO8/s1600/2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZ3a1qAcMD9wU3OZSag7WJkpNt8HoMBBS_x3QI1in9MbPAorYowC_IMlq7iPcykaCpejfQLXYWsCuthQupHIlVRBEmDsiJAIkyA6jpp9sCs3J-5b8dnWFPEVDiQCvZTirMShtzKPoBwO8/s320/2.JPG" width="320" /></a></div>
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The second application of resin fills the weave of the fiberglass cloth and gives a smoother surface. The remaining applications of resin provide enough thickness so that you can sand the surface smooth without sanding into the glass fibers of the cloth. I applied two more coats of resin until the surface was built up enough for my satisfaction. Of course, what happens when you apply a liquid to a horizontal surface? It runs, and sags, and drips, and pools, and makes a general mess. That belt sander is going to get a hell of a workout! Below is the bottom with the fourth coat applied.</div>
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Another view...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyLPlXStUlmTxlKoyAGeaNsAxgJpXLKwnMQU2BuavCePMKq5cjV7JtbW8c2LzCWfP_pQQ-q53trOcnVp4vQKZTNTEpGERNdFF_R-P9puidk-i-Kw0qdrKRrQG_bL-OrnE7TuS3eJ2_Yac/s1600/4.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyLPlXStUlmTxlKoyAGeaNsAxgJpXLKwnMQU2BuavCePMKq5cjV7JtbW8c2LzCWfP_pQQ-q53trOcnVp4vQKZTNTEpGERNdFF_R-P9puidk-i-Kw0qdrKRrQG_bL-OrnE7TuS3eJ2_Yac/s320/4.JPG" width="240" /></a></div>
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OK, I admit it, that post wasn't as short as I promised. I hope you are still with me! Now, I will let the bottom coat of epoxy cure for all of this week and hope that by next weekend it will be fully cured so I can flip the boat back over and tackle that sheer. I have a feeling I will be using this thing as a toboggan before I get to use it as a boat. *sigh* </div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com1tag:blogger.com,1999:blog-2266643419546694069.post-71901890358381822602012-10-09T02:26:00.000-07:002012-10-09T02:33:51.984-07:00Time to step up...<div class="separator" style="clear: both; text-align: center;">
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...to making the mast step.</div>
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I will jump right in because it has been a few weeks and I need to get cracking or this thing won't be done before winter!</div>
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The mast step is in fact the next step, as it were. This is the reinforced block that the bottom of the mast sits in to hold it in place, and prevent it from punching through the bottom of the boat (which is considered a bad thing.) I used 3 thicknesses of plywood to build the step, as you can see below. The centerline is marked out and the upper and lower dimensions are marked out to give it a bit of taper. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb_hE29dxgZqkoxxA6cZAXvoQQ1w4D0vQsmzGIW3DV3nCM-e9XyMheKoSOGmH9yPQhhyQoQ2Nn_eIB_5KNzpiw0Os1DdGX6gA5IfMq_L4rbuXHfnAwye1zNLmtVNcA52Yel-uXQxZAWO0/s1600/2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb_hE29dxgZqkoxxA6cZAXvoQQ1w4D0vQsmzGIW3DV3nCM-e9XyMheKoSOGmH9yPQhhyQoQ2Nn_eIB_5KNzpiw0Os1DdGX6gA5IfMq_L4rbuXHfnAwye1zNLmtVNcA52Yel-uXQxZAWO0/s320/2.JPG" width="320" /></a></div>
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Then I use the belt sander to grind it down to the lines. After that I cut through two of the layers of ply to make the cup the mast will sit in.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFM8uxkX5i6m0ZFp4RynC77f-gKCIIvfNWYl8TO0T1cYes5nORngdrFhmXjjtJ7thmY_glY-r_7PuvIfRbL3mLX1iTXY7B-5MvYhUGuhO6dlLjeg4a99qt1Gd69ioDvJ4vS7z4_1IIOB8/s1600/3.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFM8uxkX5i6m0ZFp4RynC77f-gKCIIvfNWYl8TO0T1cYes5nORngdrFhmXjjtJ7thmY_glY-r_7PuvIfRbL3mLX1iTXY7B-5MvYhUGuhO6dlLjeg4a99qt1Gd69ioDvJ4vS7z4_1IIOB8/s320/3.JPG" width="320" /></a></div>
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It is easier to see what I am talking about in this pic. This is just a test fit.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8JaCqvBoqUwAN6t1RNVINjAaR5KU60aA9ofs9CJGNt6oYKHfnY6XCot3lGwTEi51isOoAxHmNVHR5IC38eIZUnPjrTcuVJfoySyUW194M8B3FS31w7vkimFH8HmVzkATm1FvY-fMl2Zc/s1600/4.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8JaCqvBoqUwAN6t1RNVINjAaR5KU60aA9ofs9CJGNt6oYKHfnY6XCot3lGwTEi51isOoAxHmNVHR5IC38eIZUnPjrTcuVJfoySyUW194M8B3FS31w7vkimFH8HmVzkATm1FvY-fMl2Zc/s320/4.JPG" width="320" /></a></div>
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Then back to the belt sander to round over the edges.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghnUdtBB2fGu4GHuPt0RdHoniMreTLAyA0tPldsi-1BM2g8ydhwSEzGBnUJLRqu54TebJ3rl49bannEo1CWb8nThliypAijZ4G17NCJW_rZtXiWtfPvtHSYderxKIcwIF73DuVdRLP0oc/s1600/5.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghnUdtBB2fGu4GHuPt0RdHoniMreTLAyA0tPldsi-1BM2g8ydhwSEzGBnUJLRqu54TebJ3rl49bannEo1CWb8nThliypAijZ4G17NCJW_rZtXiWtfPvtHSYderxKIcwIF73DuVdRLP0oc/s320/5.JPG" width="320" /></a></div>
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And finally the stack of ply is epoxied together. Dowels epoxied in will replace the screws. Final fitting will involve checking the mast height at the thwart and adding epoxy into the bottom of the step to make a strong, hard surface for the mast to actually sit on that will not wear out from the mast pivoting on it.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNyAXVKYXR6lxMT7oplY9pJL5hr0os-0nyIkexguG56Ssrbb3SWKddu-wd0PWafF9fX4-pIGkvW-pEEC2UrC76HjhZMaimDW7UhFjtyOSEi6Oql414X2_5IutmhJNr0Tcb4Ft4C3Y88iQ/s1600/6.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNyAXVKYXR6lxMT7oplY9pJL5hr0os-0nyIkexguG56Ssrbb3SWKddu-wd0PWafF9fX4-pIGkvW-pEEC2UrC76HjhZMaimDW7UhFjtyOSEi6Oql414X2_5IutmhJNr0Tcb4Ft4C3Y88iQ/s320/6.JPG" width="240" /></a></div>
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As you remember if you saw the last post, I had just made the thole pin planks (or oarlocks as I see some people call them who sail duck punts) and they needed to be installed. This was a messy, clampy, rushed process so I will just show you the results! </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge4xbDYbKLQsawLm2qQQXW_Eyy_D8ztU8OKMbbZSxTP0I2KhU8v5GO4eCLNiwLDrVE01Pfxt5G3jWTff9PR7VXSoRaYxRrSJ3WmtYP4V13UIuTzukvOPHNFfLqC3zd-44JGH3pFyeaFPs/s1600/7.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge4xbDYbKLQsawLm2qQQXW_Eyy_D8ztU8OKMbbZSxTP0I2KhU8v5GO4eCLNiwLDrVE01Pfxt5G3jWTff9PR7VXSoRaYxRrSJ3WmtYP4V13UIuTzukvOPHNFfLqC3zd-44JGH3pFyeaFPs/s320/7.JPG" width="320" /></a></div>
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Gunwales! I had been agonizing about how to procure some hardwood for gunwales in the correct dimension since I had no power tools that could accomplish the job from rough lumber. I found some oak door trim at the local box store so I grabbed it because the idea of trying to mill lumber at this point was unthinkable. Still, it needed to be scarfed up to be long enough but that was not a problem with my now impressive scarfing skills! This job was made a lot easier by the addition of a belt sander to my tool list.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgybIG26d0Tsd3S-IbnIB_BEl7IfFSpLoeYKeTHLxmwbil07OHQ0GNaxIQqWeHoF3SzmcogV1HnLVdmuDnHKYAqQBsutT7dOF-IWe_MjRoqNau7wZjRZgHkHIoPAsAwkckDsXfmbc_mKJs/s1600/8.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgybIG26d0Tsd3S-IbnIB_BEl7IfFSpLoeYKeTHLxmwbil07OHQ0GNaxIQqWeHoF3SzmcogV1HnLVdmuDnHKYAqQBsutT7dOF-IWe_MjRoqNau7wZjRZgHkHIoPAsAwkckDsXfmbc_mKJs/s320/8.JPG" width="320" /></a></div>
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Once the gunwales were scarfed up it was time to attach them. It turns out they are much stiffer than my battens and as a result they revealed some issues in my sheer line. This became an opportunity to exercise the most important skill I have learned in this entire boat building process. The skill of letting go. In a situation where something has happened and there is nothing you can do about it, you have two options- Stop, or Go. Boats are never perfect anyway, so... Let's keep going!</div>
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It took every clamp I had and could borrow but I attached the gunwales. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfBNWwzy1TAl-WZDLhx2tY0Gwpb9dF5kMW4MosvjYI6pQyRGdrY1tUjSGejZHJaHXJAgftwEPPQ7avCZY4HSkKKqMP2BxKf-V8auWbIsZAD3V6567BL25XC3ZHBU-mDX6BDPBaHcH_3Nk/s1600/9.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfBNWwzy1TAl-WZDLhx2tY0Gwpb9dF5kMW4MosvjYI6pQyRGdrY1tUjSGejZHJaHXJAgftwEPPQ7avCZY4HSkKKqMP2BxKf-V8auWbIsZAD3V6567BL25XC3ZHBU-mDX6BDPBaHcH_3Nk/s320/9.JPG" width="320" /></a></div>
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A tricky bit is figuring out how to clamp onto a slippery triangle. The answer is attach another triangle! Sandpaper keeps it from sliding and scrap wood provides a surface to clamp to. It is a good thing I keep most of my scraps!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxtYfLl8TKExcmtTgWFgGzNeEEDRS0Kzd4NCoVMxqmTvVsEubtleexvidlGdIUcJGiyt_sEr7eBC5qiTO_dKglSlfKPx4N5nv-Q4rTmlLgB4RDqgLwomDgviX2dAD90qPKF1neKQ6Przk/s1600/10.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxtYfLl8TKExcmtTgWFgGzNeEEDRS0Kzd4NCoVMxqmTvVsEubtleexvidlGdIUcJGiyt_sEr7eBC5qiTO_dKglSlfKPx4N5nv-Q4rTmlLgB4RDqgLwomDgviX2dAD90qPKF1neKQ6Przk/s320/10.JPG" width="320" /></a></div>
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The first gunwale is on and the second one is clamped up and the glue is curing.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKn6uqnRcBIxv7fu-qvK1dAx8pR8UDKVtU7AoY6Q3DWzazv2yF4pTQ66WXNtgdbqUQaHWzjHXJgeFk7gsiHVIbtCDny0Mt4zaAfalLXktP_6xnCzS27EF7-fPqRxjqv_z_xAffM5f1EHg/s1600/11.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKn6uqnRcBIxv7fu-qvK1dAx8pR8UDKVtU7AoY6Q3DWzazv2yF4pTQ66WXNtgdbqUQaHWzjHXJgeFk7gsiHVIbtCDny0Mt4zaAfalLXktP_6xnCzS27EF7-fPqRxjqv_z_xAffM5f1EHg/s320/11.JPG" width="320" /></a></div>
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While I had the epoxy out I decided to install the mast thwart support arch. This was another area I made a mistake on waaaay back but I figured out a way to make it work. That thwart is now solid as a rock!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFUDv90_1D3sme2GsWQ9gmGQDisAPDt3sb33XdV-l2zt5qNTBJmGSLD9ZydMoMUcfnTlk-Gc8G5cjW7c9tvXxjXaTFvAksPPBPUK5VRM6OJjb9depSd8yrKgxO7-VLIb6vq3ams2JlPMs/s1600/12.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFUDv90_1D3sme2GsWQ9gmGQDisAPDt3sb33XdV-l2zt5qNTBJmGSLD9ZydMoMUcfnTlk-Gc8G5cjW7c9tvXxjXaTFvAksPPBPUK5VRM6OJjb9depSd8yrKgxO7-VLIb6vq3ams2JlPMs/s320/12.JPG" width="320" /></a></div>
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Another view...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4UPpNwhklzUepvu4o0EyC50IfRArWTD5p1iaUFznGpI6F2MZoLFMjeQLI1zqn7BWnc3atDHSDMRehEoa2fOJULp6yjHheD4comiN7571sHWUnqfv9tRMic70LKn46RpDg7ISTJWJ6nJ0/s1600/13.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4UPpNwhklzUepvu4o0EyC50IfRArWTD5p1iaUFznGpI6F2MZoLFMjeQLI1zqn7BWnc3atDHSDMRehEoa2fOJULp6yjHheD4comiN7571sHWUnqfv9tRMic70LKn46RpDg7ISTJWJ6nJ0/s320/13.JPG" width="320" /></a></div>
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And both gunwales are now on!</div>
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We are getting pretty darn close to finishing this thing, or so it seems. But then I am foolish enough to look at the "to do" list and it just never seems to get any shorter. Still to come is epoxy and fiber-glassing the bottom of the boat, flushing up the stern and the bow, planing the sheer to its final shape, and then sanding, and sanding, and sanding, and sanding, and sanding, and sanding, and sanding, and sanding, and sanding...and then painting, and etc. *sigh*</div>
<br />Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com1tag:blogger.com,1999:blog-2266643419546694069.post-57246608462719677512012-09-17T00:57:00.000-07:002012-09-17T00:57:46.880-07:00Ruffling my own feathers...<div class="separator" style="clear: both; text-align: justify;">
How is it that a project can take months longer than the weeks estimated to completion? It seems impossible to have been so optimistic about the amount of time I thought it was going to take to build the Duck Punt when it has taken so long to get to this point. I guess when you only have a few hours per week and you strive to do the best job you can it is bound to take a while but I had no idea how time consuming a boat build really is. Thank goodness I didn't take on building a tall ship!</div>
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A really exciting step happened this week and one I have been waiting a long time for. I was finally ready to mark out and cut the actual sheer line of the boat. The sheer is the curve which defines the side of the boat, and although the Duck Punt has a very subtle sheer, it is still so much nicer seeing that than seeing the ugly coffin box profile it had before. </div>
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The process involved using that long, straight, thin piece of wood called a "batten." I measured up from the bottom of the boat at specific points along the sides, as dictated by the plans, and essentially connected the dots with the batten loosely clamped at the bow and stern. Then I scribed a line along the bottom of the batten marking out the sheer on the side of the boat. Then I grabbed my trusty Festool jigsaw, took a deep breath, and cut to the line!</div>
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Defining the sheer.</div>
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A long and stressful cut!</div>
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Finally, a boat with an attractive profile!</div>
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The view from the bow. This boat is starting to look fast! (It won't be.)</div>
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The thickness of the sides with the additional sheer plank.</div>
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Next I needed to cut the hole for the mast in the mast thwart. Then a test fit of the mast thwart support, to be epoxied in after the mast step is installed. The mast step is the base that the mast sits on in the bottom of the boat. I still need to make the mast step but the thwart looks great! </div>
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Another small but necessary step was the construction and installation of the thole pin planks, as I call them. These will be drilled to accommodate the thole pin that the steering oar is braced against. As you remember if you read the last post, I had a <b>crazy</b> clamp-up for the ash laminations. A few passes over the belt sander cleaned up the glue squeeze-out, leaving a beautifully laminated square plank. </div>
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Unfortunately, the boat is NOT square which means I needed to taper the planks to match the curve of the hull. It was a simple matter of holding the plank up to the hull and tracing it's profile on the plank, then going back to the belt sander and grinding the plank to the line. Below you see there is still more work to do!</div>
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But, after a while you have a profile which matches the curve of the hull perfectly. This of course takes many test fits to get it perfect, (or close enough.)</div>
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Another big step which I wasn't at all sure how I was going to tackle was the feathering of the sheer planks. It turned out to be a lot easier than I thought! I just turned the boat on it's side and worked at the transition with a plane until I had the rough taper, and then finished feathering it in using a palm sander with an aggressive 80 grit paper. I uncovered an epoxy void, but this will all be fiber-glassed over so I am not at all worried about it. </div>
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A wicked looking bow! Of course I am going to have to soften the bow considerably, but for now I love seeing it looking all tough and mean.</div>
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Another view...</div>
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That is all for now! I figure I am about 80% done. There is still a lot to do but when I look at how far I have come I am really happy. I still can hardly believe it but I think I might actually finish this thing! Duck Punt!!!</div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-24881801797594512092012-09-03T00:11:00.000-07:002012-09-03T00:14:41.138-07:00A boat builder can never have too many clamps...<div class="separator" style="clear: both; text-align: justify;">
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Or enough, either. Ahhh, clamps. If only I had a hundred of each type! I STILL wouldn't have too many. There is always some little thing you need to clamp that takes a special type of clamp, or one that reaches a certain depth, or is affordable. OK, we all know <b>that</b> clamp doesn't exist. Let's be real...</div>
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My apologies for being SO slow with this next post. To be honest, summer finally came to Seattle, and as any Seattleite knows, you enjoy it while you can because in a matter of weeks it is gone and it is back to gray, rainy, cold, wet, misery. So, I have been enjoying the summer instead of boat building, not that boat building is not fun, but...well, anyway. Let's get caught up!</div>
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I needed to find something relatively simple to tackle since doing the sheer planks was the next major step and I needed cooler weather for the major amount of epoxy involved in that process. The thole pin planks still needed doing so that was next. I picked up a big chunk of ash and since I don't have a table saw I went to the trusty track saw to cut the laminations. It was a huge cut, barely manageable by the blade depth available, but I made it work and gave the saw a good workout.</div>
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The track saw set up for cutting the laminations.</div>
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Some of the laminations cut out.</div>
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The ridiculously complex glue-up for the thole pin plank laminations. It was already partially cured before I brought it in and set it on the hideous carpet!</div>
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Another smaller, but important, step I needed to tackle was the mast thwart. Below you can see the thwart being test fit before the glue up. This is a compound angle and plenty tricky to get it to fit "light tight." Totally unnecessary, but sometimes the cabinet-maker rears his ugly head and the tolerance of a joint becomes an obsessive compulsion. Once in a while it is OK to just go for it though, so I did!</div>
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Once the placement of the mast thwart is marked out and it is cut to fit, it is a simple matter of epoxying the thwart in place, as well as the supports fabricated to fit below. </div>
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No, this is not a seat! How many times have I been asked that since I installed this piece? Geez!</div>
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There is an arched support piece which gives bracing to the mast thwart. The easiest way to cut the arch is with router on a radius jig. First, you mark out the radius on the board using a huge compass called "trammel points."</div>
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Then you transfer the measurement onto the router radius jig and attach the board to the jig. The hole in the jig shows <i>exactly</i> where the router blade is going to cut, making it easy to double check your set-up.</div>
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Then it's a simple matter to make shallow cuts with your router until you have cut the arch out of the support. </div>
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While doing these other projects I was doing test fits of the sheer planks and checking clamping set-ups in preparation for attaching the planks.</div>
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I need more clamps!!!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQgJuuvD6cUx-ZmSIdIIjt5fja7AoQ55ydSKOTRnnlAwchl-5RAZofUQoiegQNDYobjBQVRHYGDZdIntIT7MKO9icg5PXDuJ2DmhVU3hIRp2NZnDTOu5DpSvRotu3u8j8-sBUX9bWSu54/s1600/5.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQgJuuvD6cUx-ZmSIdIIjt5fja7AoQ55ydSKOTRnnlAwchl-5RAZofUQoiegQNDYobjBQVRHYGDZdIntIT7MKO9icg5PXDuJ2DmhVU3hIRp2NZnDTOu5DpSvRotu3u8j8-sBUX9bWSu54/s320/5.JPG" width="320" /></a></div>
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The time finally came with a weather window in the 60's at night and I mixed up enough epoxy to coat the side of the boat. I decided that it would be easiest to control the process if the boat was on it's side, and I had marked out the edge of the sheer plank so I would know where to apply the epoxy so I wouldn't have excess all over the place. This step had to be done very quickly so all you see is the final product! Things went suprisingly smoothly considering the size of the job.</div>
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Naturally, the bottom edge of the plank needed the benefit of my now skillful "filleting."</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRcNmpxmfP0EXimlFe-R8uGzRZGwjwvandvwClhrtBUedQM4poEmzx2xJRVszPvc2Xwz5essvJI5QwfWLhEp6LegSWTpVAB3nc77qipzL6LnnvmcTVQuvQhKVcK-dElmyu9OZQJeABqOw/s1600/14.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRcNmpxmfP0EXimlFe-R8uGzRZGwjwvandvwClhrtBUedQM4poEmzx2xJRVszPvc2Xwz5essvJI5QwfWLhEp6LegSWTpVAB3nc77qipzL6LnnvmcTVQuvQhKVcK-dElmyu9OZQJeABqOw/s320/14.JPG" width="320" /></a></div>
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The next night I pulled all the clamps off one side, flipped the boat, and glued up the other sheer plank.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxGKe16KgKSMYjrTepNba_J2ZrKSqljeMDq_i1INzfuREfvd5bXxuRDAJe_rkYw_Cf9ksI__sXc2PW_BfczwFRR2sVHxd0wX9xS7DbCEodGmF4wKtiCrEBQwufpV3ycN8umFgyT2mje2E/s1600/15.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxGKe16KgKSMYjrTepNba_J2ZrKSqljeMDq_i1INzfuREfvd5bXxuRDAJe_rkYw_Cf9ksI__sXc2PW_BfczwFRR2sVHxd0wX9xS7DbCEodGmF4wKtiCrEBQwufpV3ycN8umFgyT2mje2E/s320/15.JPG" width="320" /></a></div>
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Another view...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiauLebb3hwO255K1gjRTosdhSQ3Eu80OoB18wHJ-jtSI5J85VcrmxjmFhSFWWkK-rKYUY1gYIWuOKY3tQC4ZRpseBqG1Q-Zs3IvLtaDgdR6pVjITp-CbC-rStHRZ1caHq3uApAF-j_pE0/s1600/16.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiauLebb3hwO255K1gjRTosdhSQ3Eu80OoB18wHJ-jtSI5J85VcrmxjmFhSFWWkK-rKYUY1gYIWuOKY3tQC4ZRpseBqG1Q-Zs3IvLtaDgdR6pVjITp-CbC-rStHRZ1caHq3uApAF-j_pE0/s320/16.JPG" width="320" /></a></div>
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Tonight I am going to go pull the clamps off and put the boat back on it's belly. The next step will be marking out the actual sheer at the gunwale and rough cutting the sheer with the jig saw. Then I will fair that curve, round over the frames, attach the gunwales and fair again. Then attach the thole pin planks and drill them, attach the mast thwart arch support, build and attach the mast step, and plank over the bow and stern caps. The last step will be to glass the bottom of the hull, sand, and paint it. The maiden voyage is not too far away on the horizon. Stay with me and we can get there together!</div>
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Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-52491236323042442642012-08-01T00:27:00.000-07:002012-08-01T03:29:25.140-07:00Installing frames rocks!<div class="separator" style="clear: both; text-align: justify;">
Tonight's installment of "Duck Punt Building 101" begins with a test fit of the sheer planks. At first I struck a line along the side of the boat indicating where the sheer plank would line up and then I just clamped the plank in place to check my fit. Spot on. Whew! Next, I need to figure out how to "feather" the sheer plank into the bow. This may require the purchase of a new belt sander. Damn, I hate buying tools. (Not.)</div>
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Below you can see the sheer plank clamped in place from the bow,</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1e0p7gF1CKdu8mLAKZx9MLeMmasjhgl7iqRykvkNQUGLPf1wqfgfSvq7AqIrPPIo-4Po2XUu6qP2TaLbqlDWQxmkTYcRWVPd6461PcqUO_6BW9sSTrYvmpoknzHyMhAGrWHO2lc3dv6A/s1600/1.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1e0p7gF1CKdu8mLAKZx9MLeMmasjhgl7iqRykvkNQUGLPf1wqfgfSvq7AqIrPPIo-4Po2XUu6qP2TaLbqlDWQxmkTYcRWVPd6461PcqUO_6BW9sSTrYvmpoknzHyMhAGrWHO2lc3dv6A/s320/1.JPG" width="320" /></a></div>
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and a view looking towards the stern. </div>
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I can hardly wait to cut the sheer to final dimension and lose that boxy, "coffin" look.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN7gTkyQr7xgav6ia-WfBP2svfgfNtkDfrpod6y4gYYGJTyGZLb88sJre2GqSywI8xtBE088YOBm_UAEmeisIWDR1m2yS6o6yuPn3cBRbxQ0oXXsOkYiLwEQkDX8Z-7q1I4zRauoM_gCM/s1600/2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN7gTkyQr7xgav6ia-WfBP2svfgfNtkDfrpod6y4gYYGJTyGZLb88sJre2GqSywI8xtBE088YOBm_UAEmeisIWDR1m2yS6o6yuPn3cBRbxQ0oXXsOkYiLwEQkDX8Z-7q1I4zRauoM_gCM/s320/2.JPG" width="320" /></a></div>
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The next step was finishing the frames. There are 6 full frames and 5 half frames. The full frames are already installed and now it is time to get the half frames installed. After cutting them to final length and width I rounded the ends over with my uber cheap, tabletop belt sander (every bit as ugly as the drill press, I will spare you.) Then I needed to round over the edges to match the full frames. The challenge is how to hold on to such a small piece when routing. I solved this by clamping a backing board (which allowed the router more surface area to travel on) and drove two small screws up through my table so they were just protruding about 2 mm. I butted the half frame up to the backing board, gave it a small tap to seat it on the screws and routed away with no movement and no problems at all. Simple and effective!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM0skXJ6fCpb5P0UVpTmYUiBLE-Ib_dxCuY88zEhjQrJJVGkWbq1LF8a6_aaj8_PG_KC4WTJ_K-ZYJZYf_OZo6d3kvzRdTBsIVadYTGMzgJOV5SCHQslzCh1IyMjVqgHBRl7xe6l0boEE/s1600/3.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM0skXJ6fCpb5P0UVpTmYUiBLE-Ib_dxCuY88zEhjQrJJVGkWbq1LF8a6_aaj8_PG_KC4WTJ_K-ZYJZYf_OZo6d3kvzRdTBsIVadYTGMzgJOV5SCHQslzCh1IyMjVqgHBRl7xe6l0boEE/s320/3.JPG" width="320" /></a></div>
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Of course, I just HAD to see the frames in there before glue up!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6Ts5vPenq5kafD89m0pfJKLCKaBw_X61ceFgUjwSkLVj9Glm51aDhdcs2fi1mt75VS7cGgIslBTVnGdmyebPdGhbeyzyhY_4Ne9Z_5WhYEcqPwUW2dp28Nu7nAhcNJoia0ZLWSosveWc/s1600/4.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6Ts5vPenq5kafD89m0pfJKLCKaBw_X61ceFgUjwSkLVj9Glm51aDhdcs2fi1mt75VS7cGgIslBTVnGdmyebPdGhbeyzyhY_4Ne9Z_5WhYEcqPwUW2dp28Nu7nAhcNJoia0ZLWSosveWc/s320/4.JPG" width="320" /></a></div>
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Once it was time to epoxy the frames in the the boat I had another challenge. When working by yourself, how do you hold the half frame while screwing it in place from below the boat? Again, we call on our friend "Big, Heavy, Rock." </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXou_Sr926jCnvmx-vq8kTX3RMmW0ZdEuAfamN510iIY_6_hSJz3LW9wwaZz2P3kbQWjejD8O02UuZmjCNEDyNr19SsNfsOOXlK6TrsLgrMTiqycdRQNoYc_RDkufCCmtzby3zYw2Buhg/s1600/5.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXou_Sr926jCnvmx-vq8kTX3RMmW0ZdEuAfamN510iIY_6_hSJz3LW9wwaZz2P3kbQWjejD8O02UuZmjCNEDyNr19SsNfsOOXlK6TrsLgrMTiqycdRQNoYc_RDkufCCmtzby3zYw2Buhg/s320/5.JPG" width="320" /></a></div>
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First I drove 3 screws up from the bottom so they were protruding about 2mm, similar to the trick I used when routing. I wetted out the area where the frame was going to be glued, and then applied a thickened bead of epoxy to the bottom of the half frame. I carefully placed it over the 3 screws and pressed it down to seat it. Then, I tri-folded a piece of sandpaper and set it on the half frame, then cantilevered a small piece of plywood over from one of the full frames and set BHR on it to hold it down. The sandpaper provided just the right amount of friction to keep the frame from twisting as I crawled around in the dirt on the ground under the hull and drove the screws into the half frames. Then I used the gloved finger to fillet the squeeze-out and in 30 minutes I had the rest of the frames installed!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4glEZYRPvRCbfwqjoiARtWBoyiZLzxonzmcI-vjhMcpirFanhD408Je4xaRCChFY70DnrVjwQMQ05rvUQh95Dh1GHc9-u3L96mWou6rr4f3hkuM4IAPfMFTTr0ysiVbH_U3r8zd1dEww/s1600/6.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4glEZYRPvRCbfwqjoiARtWBoyiZLzxonzmcI-vjhMcpirFanhD408Je4xaRCChFY70DnrVjwQMQ05rvUQh95Dh1GHc9-u3L96mWou6rr4f3hkuM4IAPfMFTTr0ysiVbH_U3r8zd1dEww/s320/6.JPG" width="320" /></a></div>
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The view of all the frames installed from the bow,</div>
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and from the stern.</div>
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Almost unbelievably, I am starting to run low on epoxy and I don't think I am going to have enough to finish the punt. Dammit! That stuff is SO expensive and I thought I was being pretty miserly with it. It is going to take a lot to glue the sheer planks on, and then there is the gunwales, the mast step and partner, the frames the thole pins go through, etc. I may have to buy another gallon, or at least another quart. $$$$$$$ At that point, I may as well coat the bottom with glass. Sigh. Will I ever finish this thing? Stay tuned to find out!</div>
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</div>Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com4tag:blogger.com,1999:blog-2266643419546694069.post-30133818132841293402012-07-23T02:31:00.000-07:002012-07-23T02:31:38.888-07:00High fashion, and a big day!<div class="separator" style="clear: both; text-align: justify;">
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It is late, so this may be a shorter post, but <b>filled</b> to the absolute brim with information and excitement! OK, that is probably an exaggeration, but let's begin anyway...</div>
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The next step in the Duck Punt build was to sand the inner chines in preparation for installing the frames. As you probably remember if you have been following the previous posts, my last experience sanding epoxy was less than fun. No, it absolutely <i>sucked!</i> So, this time I was prepared. I bought the oh so fashionable suit that you see part of below (it was way too embarrassing looking to show you a full length shot,) donned my full-face respirator and in 80 degree weather went to work on sanding the interior chines. To be honest, I didn't go all out on this process, and went to the most important of boat builder's criteria..."Good Enough." It was really hot, hard work and I was totally exhausted by the end of it. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuy6PPwMlzdgBI5heBIFi4EutAWfWSelUlph1ue6u_d5TTKlMlSYG4pg52GTIdmY_l3tDpUU4pEoDPOr82CaNz8Dn6oiKUJ8TzVfYEuAZHBCfJD-BxKQp278nWcMrSqIHbiE8EiDhE9ww/s1600/1.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuy6PPwMlzdgBI5heBIFi4EutAWfWSelUlph1ue6u_d5TTKlMlSYG4pg52GTIdmY_l3tDpUU4pEoDPOr82CaNz8Dn6oiKUJ8TzVfYEuAZHBCfJD-BxKQp278nWcMrSqIHbiE8EiDhE9ww/s320/1.JPG" width="320" /></a></div>
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Thank goodness for "Good Enough."</div>
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Once I had rested my poor back it was time to tackle that bow piece. I dug out my trusted <a href="http://en.wikipedia.org/wiki/Japanese_saw" target="_blank">Dozuki</a> and removed the bulk of the material and then used hand planes to take it down flush before giving it a good sanding. I wish I could leave it sharp like this! Unfortunately, I need to round it off a bit more to allow room to mount a bronze skid plate to take the majority of frontal impacts from rocks and beaching of the Punt.</div>
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OK, now for the exciting part! Time to mount the frames in the boat! Since I am working by myself I had to figure out a way to hold the frames in place while I crawled below the boat and drove the bronze screws in to hold everything secure while the epoxy cures. A couple of pipe clamps and a piece of 2X4 held down by a really heavy rock as a brace did the trick as you can see by this test run.</div>
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Ta-Da! The frames are installed! The squeeze out from the epoxy is turned into a small fillet using the time tested "Finger Technique." This is nothing more than running your finger down the bead of epoxy (with gloves on, of course) to give a nice, smooth fillet. Everything went exactly as planned, and it is so cool to see the Punt become a functional, stiff hull!</div>
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A close-up of the "finger fillets" prior to cleaning up, and the newly sanded chine with its fillet.</div>
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And another view of the hull with all the frames epoxied and screwed in place.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-9Fg0Dfy-GipNvuVOesaaR34rOTVr8c2c9gu90PHRt3rjiWg4C17ixA5dz9uA13lZUI608v1SlvHWvO2HLiAq2LqixMuIfYwmJ4MNucO3cveTjfO5HgkN_7N8X-7FqJB5iJwDOSL6CvA/s1600/7.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-9Fg0Dfy-GipNvuVOesaaR34rOTVr8c2c9gu90PHRt3rjiWg4C17ixA5dz9uA13lZUI608v1SlvHWvO2HLiAq2LqixMuIfYwmJ4MNucO3cveTjfO5HgkN_7N8X-7FqJB5iJwDOSL6CvA/s320/7.JPG" width="240" /></a></div>
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As soon as I have a free day I will install the half frames and then proceed to attaching the sheer plank. Fun times! So far I am really loving boat building. This is such a cool experience!</div>
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<br /></div>Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-65585938441023025752012-07-14T23:50:00.000-07:002012-07-14T23:50:03.935-07:00Down the drain, in a good way...<div class="separator" style="clear: both; text-align: justify;">
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Despite the dramatic thunder and lightning storms we have had over the last couple of days, I have managed to make some more progress on the Duck Punt build. There is nothing like working on a boat with nature playing her dramatic symphony right over your head. Even though my work space is outside, thank goodness it is covered!</div>
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Glassing and filleting of the second chine went pretty smoothly, if not actually very smooth. This time, since I had a better idea of what to expect, I kind of just slapped the epoxy in there and was more relaxed about drawing out the fillet and it went really well. At least it looks as good as the other chine, which is really all that matters at this point. Matching ugliness! </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyBrcbVE5PouSRhVYw8wekcPzNvEMbuNKNA82-oW1zWyZXu_M-thKYKp6CZgc-zQalETNifqmQQxf0Y-xmQtAwBqwEBkbXwPuhP4y2YUghgwzauDyBv7U0C0nS80wGh5Lrl7Q06CdC_dM/s1600/3.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyBrcbVE5PouSRhVYw8wekcPzNvEMbuNKNA82-oW1zWyZXu_M-thKYKp6CZgc-zQalETNifqmQQxf0Y-xmQtAwBqwEBkbXwPuhP4y2YUghgwzauDyBv7U0C0nS80wGh5Lrl7Q06CdC_dM/s320/3.JPG" width="320" /></a></div>
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Once I had the chine glassed and the epoxy was curing I moved on to the next step which was cutting out the space in the corners of the frames to allow water to drain through when the boat is heeled. I used a forstner bit in a hand drill to rough out the corner, and then used a drum sanding bit in my ultra crappy, (given to me for free,) rusted, chinese drill press and just pushed the corner in until it was the same shape as the drum.</div>
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The next day I decided that it was time to clean out my tool box and below you see the chaos that ensued. Still, a worthy project and one that desperately needed doing! (I told you that drill press was a piece of crap!)</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje8A50iZOm0gNEl4JakjNpzjN5EaK3hvsmPw0vzSukCpDewQaVepEUZzvCWklw2Jefqjuaz64iTrJLJPJBu-X8ux8_2Z3E3ERZHHEg5bxIYgamSmxOxyA7XNH84MaD5_Z409b1gq2Ffx4/s1600/1.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje8A50iZOm0gNEl4JakjNpzjN5EaK3hvsmPw0vzSukCpDewQaVepEUZzvCWklw2Jefqjuaz64iTrJLJPJBu-X8ux8_2Z3E3ERZHHEg5bxIYgamSmxOxyA7XNH84MaD5_Z409b1gq2Ffx4/s320/1.JPG" width="320" /></a></div>
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Once the tool box mayhem was under control, it was time to do some work on the frames in preparation for installing them. I stacked and batch sanded them with my palm sander, and then used a round-over bit in my router to ease the edges so they would be comfortable when I am leaning on them. Below is a dry fit to check for adequate clearance for the fillet.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0FVcf4y8M_MFfsweS2i-zIilnn4meC5uBRCZMT2gKefBVkHSv4IshSyEBCtR3BAR-0Zvs-jGp_clmPLYOxoto1EF8qwFCtGg_04l_CzTj91X0HgsdDEfYmqzPsSdwZerIy25Z1ct5v_A/s1600/6.JPG" imageanchor="1" style="background-color: white; margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0FVcf4y8M_MFfsweS2i-zIilnn4meC5uBRCZMT2gKefBVkHSv4IshSyEBCtR3BAR-0Zvs-jGp_clmPLYOxoto1EF8qwFCtGg_04l_CzTj91X0HgsdDEfYmqzPsSdwZerIy25Z1ct5v_A/s320/6.JPG" width="320" /></a></div>
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Another view...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtgx4W1tHxN8asDkjee890lwyoXXGVUQok27eYfVKPCM3lSw5J8kKtQ588-26xH6xgTiwRjsnRkVeShFZllfQPlp_Qy8hfLwcljvRtQe_z5BgPZMxdh1DA1P9TA90lFbNIv4AAFdzg1hM/s1600/9.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtgx4W1tHxN8asDkjee890lwyoXXGVUQok27eYfVKPCM3lSw5J8kKtQ588-26xH6xgTiwRjsnRkVeShFZllfQPlp_Qy8hfLwcljvRtQe_z5BgPZMxdh1DA1P9TA90lFbNIv4AAFdzg1hM/s320/9.JPG" width="320" /></a></div>
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Below is a close up showing the round-over and water drain. This view also shows the thickness of the frame. I feel like using the plywood uncut (without a joint in the corner) is going to give me a very strong frame with very little flex.</div>
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And below is another view of the boat with all the frames dry fit in place. Cool!!!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfwilJHl8vyntDPShQRQcKu9BaRHIox1gblC_0jfpAeiTr3MMi3jnlilbuNUJrsUOzdgyeRNuhxbojTLnau9FdMklgO-bZVqKvNYoejy1ihjPb0ZGGXCq9Yna2ReUjpzYB9b_uk5KfpKE/s1600/7.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfwilJHl8vyntDPShQRQcKu9BaRHIox1gblC_0jfpAeiTr3MMi3jnlilbuNUJrsUOzdgyeRNuhxbojTLnau9FdMklgO-bZVqKvNYoejy1ihjPb0ZGGXCq9Yna2ReUjpzYB9b_uk5KfpKE/s320/7.JPG" width="240" /></a></div>
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I bought a chunk of African Mahogany to use for the bow piece, (over-sized so I could shape it in place) but I had to figure out a way to clamp it on to the angled bow while the epoxy cured. I am not proud of it, but below is true innovation at work...the poor man's angled clamp. Thickened epoxy and a huge rock, I really am a boat builder now!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWnv95uj5mmNeBeohH-Vqmscdc1QV11kqT0XMXH41y2CaKWRNrdZgdFuXkztogpUuQx0ifMAtEOzNsAA4HYMivaZyBzk6EgnmN7uxJXcnpQiuVh3evOkZP8R1DiUYukqpHJcNAVBg7npI/s1600/10.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWnv95uj5mmNeBeohH-Vqmscdc1QV11kqT0XMXH41y2CaKWRNrdZgdFuXkztogpUuQx0ifMAtEOzNsAA4HYMivaZyBzk6EgnmN7uxJXcnpQiuVh3evOkZP8R1DiUYukqpHJcNAVBg7npI/s320/10.JPG" width="320" /></a></div>
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Once the epoxy cures in the chines I will begin sanding the interior to smooth it in preparation for paint, and then I can attach the frames. I can then shape the bow piece at my leisure and glass it for extra impact protection. Phase three will then be complete! Then it will be time for side panels, gunwales, oar chocks, mast partner, etc, etc, etc...</div>
<br />Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com1tag:blogger.com,1999:blog-2266643419546694069.post-30470482533620609562012-07-09T02:04:00.001-07:002012-07-09T02:04:55.086-07:00It wasn't my fault...I was framed!<div class="separator" style="clear: both; text-align: center;">
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Finally, we have had some nice weather in Seattle allowing me the opportunity to make some more progress. As we finished "phase two" the boat sides were attached to the bottom with an external coat of glass and epoxy and the boat had finally been "flipped." Now we begin working on the interior!</div>
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I wanted to build in some reinforcement to the bow and stern posts so I rough cut a couple of pieces of ply which will be glued in later. The tricky part is, I don't have a bench vice (hell, I don't even have a bench!) So how do you hold a piece of plywood vertically so you can work on the edge? You dig out a couple of clamps and get creative!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOmiBvFpJ2gZOeJr9QRoMf08sZIQOO7HWhsBsDksZm9J9QK0uShxBcW0B41Dxt-gjNA3D5feH_R93Svz-xGAxeTCc8fYJQ8s3ZO5drn-OBAqem9zihXcG5jmo2lIOfPhSwlP_UIr19sQU/s1600/1.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOmiBvFpJ2gZOeJr9QRoMf08sZIQOO7HWhsBsDksZm9J9QK0uShxBcW0B41Dxt-gjNA3D5feH_R93Svz-xGAxeTCc8fYJQ8s3ZO5drn-OBAqem9zihXcG5jmo2lIOfPhSwlP_UIr19sQU/s320/1.JPG" width="320" /></a></div>
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In the next photo you can see the rough cut inserts for the stern post set in place. This will have a cap over it at some point in the future when I am doing final finishing of the boat.</div>
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Knowing that I was going to have epoxy in the chine soon it was time to lay out the frame placement in the boat so I could work on them while the epoxy was curing. It was a simple matter to measure out from the plans where to place them and mark out the placement clearly with a sharpie. My fancy rope clamps come in handy once again!</div>
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Now it is time to epoxy fillet and glass the internal chine. Someone gave me the tip of turning the boat on it's edge so the epoxy would flow down into the chine which was a brilliant idea and worked like a charm. I wetted out the seam at the chine first and then came another first for me, doing an epoxy fillet. You mix a thickening agent into the epoxy making a consistency similar to peanut butter and lay it into the chine in a thick clump. Then slowly and smoothly, using a round edged tool designed for this purpose, draw the tool along the thickened mixture making what is hopefully a nice, smooth, curved fillet which makes a round transition at the joint and reinforces it for strength. Then scrape the excess off and below you see what you have...the worlds ugliest fillet!
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A closer look...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcb_SFBAvvYxEpHq_0kCc0eiSY_86msWSsPcu9ilMUt7Bf7ZEJroc29-PYCPLcPZPuEhoBbPt-02MzldLlA65DLEf8asFSERT_M6FSdZR-5S-6jksn9PGAAfeweQH3BChyphenhyphenBfQZp93aLsw/s1600/5.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcb_SFBAvvYxEpHq_0kCc0eiSY_86msWSsPcu9ilMUt7Bf7ZEJroc29-PYCPLcPZPuEhoBbPt-02MzldLlA65DLEf8asFSERT_M6FSdZR-5S-6jksn9PGAAfeweQH3BChyphenhyphenBfQZp93aLsw/s320/5.JPG" width="320" /></a></div>
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After my previous learning experience with epoxy I now know that you must try to get all your layers done in one session so after the epoxy had turned tacky and set up a bit the next step was to lay fiberglass cloth into the joint. After my frustration last time with the thick edge of the glass tape I cut that damn seam off and had much better luck fairing it out. It is still ugly as you can see below but much better than last time. I also filled and faired the split seams at the stern of the boat.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAG30-dCYi2Ol7W6YYplAOTSDNFxV0twRwL-2c4B3gMKKL7udEtFHpovgg2UWrwWp8VQ-6KNoifiI5YxDpZRdxUEpkYdbZPuoxAO1TgLCCuVfNKELcMtY6lBwHosgoIctN_-xBbFNQkIg/s1600/6.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAG30-dCYi2Ol7W6YYplAOTSDNFxV0twRwL-2c4B3gMKKL7udEtFHpovgg2UWrwWp8VQ-6KNoifiI5YxDpZRdxUEpkYdbZPuoxAO1TgLCCuVfNKELcMtY6lBwHosgoIctN_-xBbFNQkIg/s320/6.JPG" width="320" /></a></div>
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While waiting for the epoxy to cure I had enough time to rough cut out the frames. I used the same frame pieces that I had used for the jig so I saved some money there, and they were already the correct shape and just needed some re-sizing. I marked out the interior shape and roughed them out with the jigsaw. Being one piece like this will give them significantly more strength too. A poor man's version of the much preferred grown knees in traditional ship building.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizhlVUyQ0S3eQTYz8lJJ3KRwwaZDIuVXXsu_lnZWS_mV53VR8w-gAZpS2Hr6kosElmNDqhDmyqhTyFqap8hZUiRF2_l8GkawIZgVQkQ9Ep0MfZ4RGQseT5lOWNkDmg5HN5W1A-KkqHcCI/s1600/7.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizhlVUyQ0S3eQTYz8lJJ3KRwwaZDIuVXXsu_lnZWS_mV53VR8w-gAZpS2Hr6kosElmNDqhDmyqhTyFqap8hZUiRF2_l8GkawIZgVQkQ9Ep0MfZ4RGQseT5lOWNkDmg5HN5W1A-KkqHcCI/s320/7.JPG" width="320" /></a></div>
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Then I planed them smooth using my new "table vice" setup. I still need to fair the inner curves, round over the edges, and decide the shape of the water channels...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPQcjsJJRNh4LNqlgiZPUx4p3PsulQL3X1BgMxViX5IK38umUgV1htpZbiDW0eEggx1DnS2N1lNhQLklK-kLhCtqpnRo0mMzRmbm8C_4ZbP4TjJkvCXe-ZySfXDTzDQnsjknHFj3JTHvc/s1600/8b.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPQcjsJJRNh4LNqlgiZPUx4p3PsulQL3X1BgMxViX5IK38umUgV1htpZbiDW0eEggx1DnS2N1lNhQLklK-kLhCtqpnRo0mMzRmbm8C_4ZbP4TjJkvCXe-ZySfXDTzDQnsjknHFj3JTHvc/s320/8b.JPG" width="320" /></a></div>
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Of course at this point it is impossible to resist setting the frames in the boat and getting a sense of what it is going to look like. I am really psyched to do this because at this point the boat is in a bit of an "ugly duckling" phase with clumpy epoxy and lumpy glass and splotchy resin everywhere. It is nice to get a perspective on how cool it is going to be once I get past this point! Below is the view from the bow...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7xixQUuIP_yc9kJhuMb7Gs1weut3iscpFZo3OPBSl5cUImpOeS0xa7j4Cli3q9A0VfmK9nx7Odx5Gbx3r1NLyh1Eh0Vmsn5WTqulYG0uJNe3MPrQUJ-_ERmnfJwvpBUodcEgZdS6wqsk/s1600/10.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7xixQUuIP_yc9kJhuMb7Gs1weut3iscpFZo3OPBSl5cUImpOeS0xa7j4Cli3q9A0VfmK9nx7Odx5Gbx3r1NLyh1Eh0Vmsn5WTqulYG0uJNe3MPrQUJ-_ERmnfJwvpBUodcEgZdS6wqsk/s320/10.JPG" width="240" /></a></div>
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...and from the stern.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimSMmb8yV7Iouklx-pO-utWs55Pxb07UGSa-QddOqyVcUmoZkktabCBRRqPWnINUPay8EBwW1tcycJBnP21gtXhv4ZfcU3nvywsJAujM05TVHuEQ6-dFyE8GeH4sDuFgpLp8OcdJdyfbY/s1600/9.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimSMmb8yV7Iouklx-pO-utWs55Pxb07UGSa-QddOqyVcUmoZkktabCBRRqPWnINUPay8EBwW1tcycJBnP21gtXhv4ZfcU3nvywsJAujM05TVHuEQ6-dFyE8GeH4sDuFgpLp8OcdJdyfbY/s320/9.JPG" width="240" /></a></div>
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A closer look below with the now cured fillet. I only had time to do one side so it will be next weekend before I will have enough time to do the other side.</div>
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This boat is starting to really come together! Stay tuned for more to come...</div>
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<br />Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-65022321931033521302012-07-02T02:35:00.000-07:002012-07-02T02:44:39.433-07:00Phase 2 done...flipping with joy!<div class="separator" style="clear: both; text-align: justify;">
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Tonight was an exciting night! But, first things first. We have a lot of catching up to do!</div>
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It has been a long time since my last post, my apologies. The truth is, I have been super busy with work and the weather has been just awful. No excuse really, but it does sap ones motivation. Still, slow progress has been made so let's begin with the first of a lot of photos showing what has been happening.</div>
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As you may recall from the last post, I had planned on using a router and a flush trim bit to trim the bottom panel to the side panel's fair curve. I discovered that the side panels were much too flexible at this stage to support the router bit enough to make a clean cut so, it is back to the trusty hand tools! I cut the bottom panel as close as possible with my jigsaw and then trimmed it flush with a selection of hand planes held vertically. This was a TON of work but produced a nice edge as you can see in the following two pictures.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnk3uDaMf3jDTjW93KCtysUuJ6U4zAmhTv-ZBeKfMzJuTG9uY7NbGZPwpnAwiiGP6CV0kWwe9R-6gkmDDpr6SYK0ALebE3wfrY_TH0O7AVPjGktDtRbqCMjbwx1gfCjLtOTm4Ote9rtsM/s1600/IMG_1.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnk3uDaMf3jDTjW93KCtysUuJ6U4zAmhTv-ZBeKfMzJuTG9uY7NbGZPwpnAwiiGP6CV0kWwe9R-6gkmDDpr6SYK0ALebE3wfrY_TH0O7AVPjGktDtRbqCMjbwx1gfCjLtOTm4Ote9rtsM/s320/IMG_1.JPG" width="320" /></a></div>
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Swinging a jointer plane side to side along 32 feet of boat edging is unbelievably exhausting!
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I then rounded the chine over with sandpaper to make a soft curve that the fiberglass tape could easily mold over. At this point, we are ready for glassing! Below you will see the boat prepped and ready, with a light line drawn on as a reference for how far down to run the epoxy wet out.</div>
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As with so many steps on this boat, this is my first time using epoxy and fiberglass together. I can't say that it was a fun experience, I hate working with epoxy. Nasty stuff and not good for you, avoid any and all contact with it! This was another significant learning opportunity and I made huge mistakes here by not following the manufacturer's directions closer and having limited time. The first lesson I learned is evident in the two following pictures and you can see it in the distinct white line on each side of the glass tape. That is a seam that holds the stitch of the tape together and should be cut off before the tape is applied, or after, but <b>definitely</b> before the epoxy cures. That, and you must make sure you apply all coatings necessary to fill the weave before the epoxy fully cures. You guessed it...I ran out of time and had to let it cure.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ6v2w40SGM3g_MImaxrtafG7Q7A19BmDbxCUu_lHHibiDq2_0wuH9S9r0_J3RbLeWjo5hyTzaESbLYAcDU-UEUoFVN-_Xuty2TPJgijj1heoWKK9x7bivtoaiIm_Ewj2m8BXu6zEliK8/s1600/IMG_4.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ6v2w40SGM3g_MImaxrtafG7Q7A19BmDbxCUu_lHHibiDq2_0wuH9S9r0_J3RbLeWjo5hyTzaESbLYAcDU-UEUoFVN-_Xuty2TPJgijj1heoWKK9x7bivtoaiIm_Ewj2m8BXu6zEliK8/s320/IMG_4.JPG" width="240" /></a></div>
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The horrible white line is very evident in this picture below.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihuD3kzxrsKZNwzlDryNr4a9KhQlizLE-sOa9Um1V8fen7MiPsdowZ5-hMxdek1cRG7OPiY2Yd6It6jnJinnnUJY3GdjOw06Rz_iIuXbqIHaOpa0pGPPfzl33ss6pTP8qIcp56Xz5Uf70/s1600/IMG_7.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihuD3kzxrsKZNwzlDryNr4a9KhQlizLE-sOa9Um1V8fen7MiPsdowZ5-hMxdek1cRG7OPiY2Yd6It6jnJinnnUJY3GdjOw06Rz_iIuXbqIHaOpa0pGPPfzl33ss6pTP8qIcp56Xz5Uf70/s320/IMG_7.JPG" width="320" /></a></div>
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The result of my two mistakes here was the need to do a MASSIVE amount of sanding to fair the epoxy into the plywood. My third mistake was not covering myself from head to toe in a tyvek suit to keep the dust off. I wore an air filter and glasses but I was literally covered in epoxy dust. That is a big mistake that I will NOT make again. </div>
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I guess the unfortunate necessary steps produced the result I needed though and the epoxy was eventually faired out. A rough sanding and a thorough washing removed the amine blush and dust and prepared the surface for the subsequent coats necessary to fill the weave of the fiberglass cloth and build up the thickness of the epoxy enough so it can be sanded smooth to proved a good surface to paint.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCTy0ECMB5oeDLydyrUyNmCb0HKjyJ8wSalbxsCNJ9QcNK4LA3jvE8NOgm_7dHsuRGysM_zNawBtwXc9UfYe36K-kJJ7RnSj5xp_uOKOqs2KAdXobvahdMfUx22bmpupGKZyMA4DLzvYk/s1600/IMG_5.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCTy0ECMB5oeDLydyrUyNmCb0HKjyJ8wSalbxsCNJ9QcNK4LA3jvE8NOgm_7dHsuRGysM_zNawBtwXc9UfYe36K-kJJ7RnSj5xp_uOKOqs2KAdXobvahdMfUx22bmpupGKZyMA4DLzvYk/s320/IMG_5.JPG" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAflHUzVoKa-KzwVFdAvq1LxFIPB6V8HBm9ShhYqUYTp6_xoj6aVErZoXE5ytwcQDYJLtv2WC1hOi54XgFOw5P_htroI6S-fzQJS7HkBmhMFCX_w4CjJKbKNLrNpLL5-eRPhyphenhyphenUkNCFIbc/s1600/IMG_6.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAflHUzVoKa-KzwVFdAvq1LxFIPB6V8HBm9ShhYqUYTp6_xoj6aVErZoXE5ytwcQDYJLtv2WC1hOi54XgFOw5P_htroI6S-fzQJS7HkBmhMFCX_w4CjJKbKNLrNpLL5-eRPhyphenhyphenUkNCFIbc/s320/IMG_6.JPG" width="320" /></a></div>
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In the photo below I have applied a couple more coats of epoxy to the seams to fill the glass weave, and tipped the coats out thinner and thinner as it moves away from the edge.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif3vf_G48soPED90Z3GBqhz-SBaUHzFX1H7t3DNK6vi6kM-NtlA5BqbknOOGJHYCXCqfhFxG6sXjDOJyrt3wAd8MR6aVwYW3KDka9COjJPgbvkrOhvyGWgVRqnnYrJNX7VV9OQ7iNfEDo/s1600/IMG_7b.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif3vf_G48soPED90Z3GBqhz-SBaUHzFX1H7t3DNK6vi6kM-NtlA5BqbknOOGJHYCXCqfhFxG6sXjDOJyrt3wAd8MR6aVwYW3KDka9COjJPgbvkrOhvyGWgVRqnnYrJNX7VV9OQ7iNfEDo/s320/IMG_7b.JPG" width="320" /></a></div>
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The epoxy coating is now thick enough to sand smooth without affecting the glass below.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTXCfh_x3-lxhS0aoQjVYeNPJv-Bl-GXm0zoY0_KzaRWYRQ-0T6Zq-QDRbgKmwaFzyQ6-rFxbC3e9b_QcJFkpYY7OONW5I5rc1zN2gbE9HTgCFljtyyPqMSntdsHE6H2yRHbPx46w5DBA/s1600/IMG_8.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTXCfh_x3-lxhS0aoQjVYeNPJv-Bl-GXm0zoY0_KzaRWYRQ-0T6Zq-QDRbgKmwaFzyQ6-rFxbC3e9b_QcJFkpYY7OONW5I5rc1zN2gbE9HTgCFljtyyPqMSntdsHE6H2yRHbPx46w5DBA/s320/IMG_8.JPG" width="320" /></a></div>
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While waiting for these epoxy steps to finalize I had the opportunity to continue my scarf practice and I think I am getting the hang of it, if I say so myself. These are good scarfs! These sheets will be the upper reinforcement planks for the Duck Punt's sides.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkzGRstPr9p5DcHLXL1dxpbGZd1sxnta9COypekeVl1e0uZSd9lJoO6HvGl89TQVMz0lnhPFwGQ0AkR0UECb6fjph5y6kjdt6LUu_RRYfxcJCR_OwM7hnq69YRMyFQKSrZRoGVJlirguE/s1600/IMG_9.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkzGRstPr9p5DcHLXL1dxpbGZd1sxnta9COypekeVl1e0uZSd9lJoO6HvGl89TQVMz0lnhPFwGQ0AkR0UECb6fjph5y6kjdt6LUu_RRYfxcJCR_OwM7hnq69YRMyFQKSrZRoGVJlirguE/s320/IMG_9.JPG" width="320" /></a></div>
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Below the scarfed together planks are stacked, marked out, and cut to shape, then faired with those ever so useful hand planes.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAwWY7w8GgAr8MrsC4_njsjN0XGzt0jU9zYgUFM4Xn9Qur5ENawIFtKrbpFRm_OaXcGGTzsz2sQRjstn3TPS3ynmbC3VqArLAj4p0nFJV7SoZEAOIdG6zCcb_9azEq05Wfj6nAyJbODhc/s1600/IMG_10.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAwWY7w8GgAr8MrsC4_njsjN0XGzt0jU9zYgUFM4Xn9Qur5ENawIFtKrbpFRm_OaXcGGTzsz2sQRjstn3TPS3ynmbC3VqArLAj4p0nFJV7SoZEAOIdG6zCcb_9azEq05Wfj6nAyJbODhc/s320/IMG_10.JPG" width="320" /></a></div>
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Finally for the exciting part! At this point it was time for the satisfying step of lifting the boat off of the jig and flipping it right side up. This is a big step because it allows the boat builder their first opportunity to see the rough shape of the boat and start imagining how it will look when finished. One has to control ones desire to jump in the boat at this point to "see how it feels."</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT_uUZvoIq1-cYp8WezAY_CX-r28-kWbWRG3j18tGP2M6PXLlxGo_XDs3JVQZtpDckdxLYNOeGPLkCTO9Sw6RvFhWvp6QMeiu2DfAh74Y_dyrLB6kOsneIPYF_FpuTxho_KQJ7UCQ6mN4/s1600/IMG_11.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT_uUZvoIq1-cYp8WezAY_CX-r28-kWbWRG3j18tGP2M6PXLlxGo_XDs3JVQZtpDckdxLYNOeGPLkCTO9Sw6RvFhWvp6QMeiu2DfAh74Y_dyrLB6kOsneIPYF_FpuTxho_KQJ7UCQ6mN4/s320/IMG_11.JPG" width="320" /></a></div>
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Weird how night time lighting makes things look blue from certain angles...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYKbqnoroG6zs_VxRznqFUQ0O5fsOfvBBxfvD0a2KDbbWohaXoS6tOLKYw1Waguvb4fhdqpPcRDmL-PAiLkOZqqM6fzhJPyP6swq9aw538ySUT8yM9VRP7udsAWNaxHp6USludzo-nI2o/s1600/IMG_12.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYKbqnoroG6zs_VxRznqFUQ0O5fsOfvBBxfvD0a2KDbbWohaXoS6tOLKYw1Waguvb4fhdqpPcRDmL-PAiLkOZqqM6fzhJPyP6swq9aw538ySUT8yM9VRP7udsAWNaxHp6USludzo-nI2o/s320/IMG_12.JPG" width="320" /></a></div>
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I am really excited!</div>
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So, I consider this to be the end of phase two. Phase one was building the jig and installing and leveling the station molds. Next will be glassing the inside seams and framing the interior. </div>
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I am starting to think I may actually finish this thing. Duck Punt! Duck Punt!</div>
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<br /></div>Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com2tag:blogger.com,1999:blog-2266643419546694069.post-44937926274823014202012-06-11T01:05:00.000-07:002012-06-11T01:12:38.216-07:00Problems and solutions...<div class="separator" style="clear: both; text-align: justify;">
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Well, one does not become a scarfing master with one successful example. In fact, usually one becomes skillful at something by making mistakes and learning from them. I should be well on my way then because my second attempt at scarfing for making the bottom panels of the hull was, shall we say...less elegant. I think only having two panels in line rather than the four I had last time makes it much harder to keep your scarf in registration and cut a clean angle. It was ugly but I patched it up, sanded the heck out of it, and all is well that ends well. At least in scarfing.</div>
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I made some good progress today, and learned some more things to boot. The bow and stern were epoxied and screwed onto their respective posts. I was happy to take this step because it meant I no longer was going to be moving those side panels around and was actually going to start building this darn thing! </div>
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The bow, screwed and glued. No turning back now!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrQJin2ckKPhhtG25dQkiIrzCBRb3_2Y2JEQOlrrm2DVNt5PPOCJO3Co9TTcL4K04eRe__ksKgvm7kK-zhLy6cE7Ljrmrvyfvhyphenhyphen3Kd4I6UZdeaoAugh78EecXWNHwhoHDp5BDvSQtqM9A/s1600/epoxybow.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrQJin2ckKPhhtG25dQkiIrzCBRb3_2Y2JEQOlrrm2DVNt5PPOCJO3Co9TTcL4K04eRe__ksKgvm7kK-zhLy6cE7Ljrmrvyfvhyphenhyphen3Kd4I6UZdeaoAugh78EecXWNHwhoHDp5BDvSQtqM9A/s320/epoxybow.JPG" width="240" /></a></div>
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The stern, also screwed and glued, and showing the saw kerf which allows the stern plank to fan out. Yes, I realize the epoxy looks hideous. Trust me, it will sand out and look fine.</div>
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<span style="text-align: justify;">When stepping back to admire my work I could see something which gave me pause. In fact, it gave me fits! The side panels pulled away from the frames and I could not figure out why. I finally discerned that I needed (once the epoxy had set up) to unscrew the bow and stern posts from the jig so the sides of the boat could relax into their final shape. This led me to discover that the boat needed to be flexed upward a bit to essentially pull the sides back in to the frames. Hard to describe, and hard to discover, but I did finally get the side panels fitting smoothly, and fairly, against the frames without having them forced into place, by wedging a 2X4 under the middle frame, lifting the center of the boat and flexing in the sides. Thank goodness for that thinking chair I spoke of before. It is getting good use!</span></div>
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Using my trusty batten to check the fairness of the side plank as it lies against the frames. There is a very tiny gap at the bow and stern but I would say this is pretty good!</div>
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The next step was to drive a single screw top and bottom at each frame to hold the side panels in shape. Then I was able to lay the bottom panel on top of the side panels and scribe around the entire boat, leaving and inch or so to be trimmed during final fitting of the bottom. My trusty <a href="http://www.amazon.com/Festool-561443-PS-300-EQ/dp/B004REJ678/ref=sr_1_1?ie=UTF8&qid=1339402306&sr=8-1" target="_blank">Festool jigsaw</a> made short work of cutting to the line and the result is...</div>
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I have built a coffin.</div>
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I hope this is not a harbinger of things to come! ;-) </div>
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And that is plenty for this installment. Next, when I get a free day, I will reference screw the bottom panel to the frames, and using a pattern bit in my router trim the bottom panel flush with the side panels. Then epoxy tape the bottom to the sides and I can turn the boat over and start framing the interior! </div>
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Thanks for following along. More updates to come as soon as I can get some more time to work!</div>
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<br />Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com3tag:blogger.com,1999:blog-2266643419546694069.post-66242975554634329642012-06-02T22:34:00.002-07:002012-06-02T22:40:57.065-07:00Me as a boat builder is side splitting!<div class="separator" style="clear: both; text-align: justify;">
Well, it has been a week of crappy weather and busy times with <a href="http://www.robmarcus.com/" target="_blank">playing music</a> and work leaving me with little time left to work on the Punt. I managed to get quite a bit done today though so here are the updates.</div>
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If you remember at the end of the last post I was preparing to do "<a href="http://en.wikipedia.org/wiki/Scarf_joint" target="_blank">scarf</a>" joints on the side planks, joining two 8 foot long planks into one long 16 foot plank to make each side of the Punt. While daunting for a first timer on expensive marine plywood, it turned out to be relatively simple, although a lot of work using only hand tools. (Perhaps I see a Festool power planer in my future...) The process is just marking back from the edge a ratio of at least 8 to 1, which in my case turned out to be 48 millimeters since I am using 6mm ply. So, 48mm is close enough to 5 centimeters so I marked back on each board 5cm and then staggered them back so each edge lined up with the mark beneath it. Then it is simply a matter of cutting, sanding, grinding, routing, or planing at the angle shown and connecting the top line to the bottom front edge as you see below. The plies really give you a nice point of reference so you know where you are at with the scarf. Borrowing my friends jointer plane helped a lot but if I had to do a lot of these I think I would find a quicker way.</div>
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Of course, the next step is the glue up. I have a lot of experience with this from furniture making and it is still always stressful. I used a slow set epoxy to give me plenty of time to get things placed just where I wanted. Unfortunately, it was colder than I would have liked and I worried that the epoxy was not going to fully cure but mother nature supplied me with one warm day and so glue up happened. You have to make sure you don't clamp so hard that you starve the joint but hard enough to get things flat. a large rock, two clamps, and a 2X4 does the trick. Wax paper keeps the squeeze-out from gluing the planks to the table!</div>
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I did use packing tape along the joint so squeeze out would peel off easily but...forgot to put it on both sides of the seam. I won't make that mistake again! Still, the squeeze out is not too bad, and leads us to the next inevitable step....</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi72Qws-DuT5-9IgRoqU-AxIPmzAw8Jfd02p2UaL8mfp-nUj1ekbGC7XagufjirGBBUUw_CBl5s5zUHutx7qMGNDEpQWQgAKVvqH7Z-WBt4VK-2Uxvzir1zIkEY-lfeyZ3N5wHy2utoUXk/s1600/Squeezeout.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi72Qws-DuT5-9IgRoqU-AxIPmzAw8Jfd02p2UaL8mfp-nUj1ekbGC7XagufjirGBBUUw_CBl5s5zUHutx7qMGNDEpQWQgAKVvqH7Z-WBt4VK-2Uxvzir1zIkEY-lfeyZ3N5wHy2utoUXk/s320/Squeezeout.JPG" width="320" /></a></div>
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Sanding. And sanding, and sanding, and sanding. Propping the joint up a bit insures I am only sanding the epoxy and not the plywood. Once the hard edge disappears, you know you are flush. When seen on edge (I wasn't able to get a decent picture) the joint is invisible. So cool!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTOd332t1XRwSVuauI5XA_M6c-qai_fdNveUO8bLcJf74aeAeM8uBw5y17s3GYx5q9CrPPhFv5dkNF4ghsXUz1OHHhjx5yqTgZ6ty6m-8rJ7G9ogDbcZiElF1UDnxt-XDll8tcIkEHeqo/s1600/smilingsander.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTOd332t1XRwSVuauI5XA_M6c-qai_fdNveUO8bLcJf74aeAeM8uBw5y17s3GYx5q9CrPPhFv5dkNF4ghsXUz1OHHhjx5yqTgZ6ty6m-8rJ7G9ogDbcZiElF1UDnxt-XDll8tcIkEHeqo/s320/smilingsander.JPG" width="320" /></a></div>
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Now it is back to using those ever so useful battens. There are several possibilities for how to hold the side panels in place while doing this but rope works for me. The side panels are cut a bit over size and the batten is clamped inside along the top (or bottom depending on how you look at it) of the frames. Then I strike a pencil line along the underside of the batten to mark the actual chine, which is the bottom edge of the boat. I guess technically the chine will be on the bottom panel but you get the idea.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgerT21sgh-VHZ3jWImdegEQy0uOLTaddXW2aFYHdiWM3nvryGLpWCUc9p7B3NwD-_1Wn0RWuG5a6-wYwXpOKl4r5zoOe85FO_sdTxH3YbD03un4TWlP9fAL9zu0L3pY9_fkR0gGlJ1Hpo/s1600/batten.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgerT21sgh-VHZ3jWImdegEQy0uOLTaddXW2aFYHdiWM3nvryGLpWCUc9p7B3NwD-_1Wn0RWuG5a6-wYwXpOKl4r5zoOe85FO_sdTxH3YbD03un4TWlP9fAL9zu0L3pY9_fkR0gGlJ1Hpo/s320/batten.JPG" width="320" /></a></div>
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Here is another view of the batten clamped in place. Hey, wait a minute! That is starting to look like a boat!!! Once the line is struck, I stacked both side panels together and using my trusty circular saw cut both at the same time to the line. A little fairing with the jointer plane and the chine is cut. Hmmmm, that little triangle area at the back is looking kinda weird...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXqEom3opwXR56Ae6r_5cd5h3QAXDYOVxYindvz-8UZHsziVQ3Cvgad_0xKpMwCRveTWrBqErqt-p04eg_W1RXgdwNMBBV9grIljYTQT7lOIwaVxQMyEJhOMDdU94UGALHj9ImoQUke7o/s1600/endview.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXqEom3opwXR56Ae6r_5cd5h3QAXDYOVxYindvz-8UZHsziVQ3Cvgad_0xKpMwCRveTWrBqErqt-p04eg_W1RXgdwNMBBV9grIljYTQT7lOIwaVxQMyEJhOMDdU94UGALHj9ImoQUke7o/s320/endview.JPG" width="320" /></a></div>
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I cut the side planks to match the angle of the bow post and beveled the post to match the angle of the planks as they come into it. And now back to that stern piece. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzBsLHkuT-Tom_BVu5KHS1zMtuYuv0LXsEIIYxfBJY8nkLQlNVs7D9jQsm-EuVVKPJ2DlpFvPw0zFkeELMxgNWGq21VjpLnxSgt1_azaxZGoNsUzJmGQAyfaCM6fNMwngy0oIs52Lxets/s1600/bow.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzBsLHkuT-Tom_BVu5KHS1zMtuYuv0LXsEIIYxfBJY8nkLQlNVs7D9jQsm-EuVVKPJ2DlpFvPw0zFkeELMxgNWGq21VjpLnxSgt1_azaxZGoNsUzJmGQAyfaCM6fNMwngy0oIs52Lxets/s320/bow.JPG" width="320" /></a></div>
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The stern plank is split (side splitting, get it?) and made ready to mold to the stern post, giving it that characteristic Duck Punt stern. My dozuki japanese saw leaves an almost invisible kerf, perfect for this cut. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5osqla3OlS-VeYn4O1MpXUVQ1hLtPrkzsrbuejQZMk2JrHjy1EfpR1wlO3EBoebh61co4gzqipkb7FWDCJDfN5I_PrXO8Kxqap0LjvRrwGW-5xcy6qeVOEC9KwPXLC-j9tmYTDjxRodc/s1600/splitsides.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5osqla3OlS-VeYn4O1MpXUVQ1hLtPrkzsrbuejQZMk2JrHjy1EfpR1wlO3EBoebh61co4gzqipkb7FWDCJDfN5I_PrXO8Kxqap0LjvRrwGW-5xcy6qeVOEC9KwPXLC-j9tmYTDjxRodc/s320/splitsides.JPG" width="320" /></a></div>
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The next step will be bevelling the stern post to match the angle that the stern planks come into it at, scarfing the bottom panels together, and then I can attach the bottom to the sides! More to come so please stay tuned, and your comments are welcome!</div>
<br />Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com3tag:blogger.com,1999:blog-2266643419546694069.post-83069011854965719332012-05-25T23:49:00.000-07:002012-05-25T23:49:03.493-07:00All's fair in love and war...<div style="text-align: justify;">
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...and boat building. Although the fairness here refers not to any kind of equanimity but much more importantly to the boat builder's aesthetic of a nice smooth curve without any bumps or deviations. But, I am getting ahead of myself.</div>
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A trip today to Seattle's Fisheries Supply served to empty my wallet of another $150. What did I get for my investment? A gallon of epoxy resin and hardener, and 100 bronze screws. Who ever said building your own boat was cheap?! Ouch...</div>
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The sail arrived for the Punt this week. Much sooner than anticipated so many thanks to <a href="http://www.intensitysails.com/" target="_blank">Intensity Sails</a> for the quick turnaround. Damn, I better get busy and build a boat! The sail looks well constructed and I am really looking forward to trying out the sprit rig. It has a great reputation for providing a lot of drive and power without excessive heeling which is important in a boat with no ballast other than a "solidly built" skipper.</div>
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Now, before you think after looking at the pictures below that nothing much has happened, let me say that if I had any hair on my head before, it would be all gone anyway from all the head scratching I have been doing getting to this point. Remember, "first-time boat builder." They say the most important tool in the boat builders shop should be a comfy chair and I could not agree more because, believe me, you are going to be spending an inordinate amount of time sitting in it looking at you work. This is not because you are admiring what you have done, but more because you are wondering how in the hell you are going to figure out how to do what you need to do next. Now, take a look below at that little triangle shaped piece at the stern of the jig. Essentially, I am having to modify the design to accommodate the fact I am using 6mm ply for planking and therefore some fidgeting went on creating that little piece. The Punts in Mersea are much heavier built and I want to keep this one light enough to be car-toppable, hence the head scratching up to this point creating that little triangle. Thanks again to Stan for his advice on this tricky little bit. I eventually just went for it and I will hope for the best. Damn, I AM becoming a boat builder!</div>
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Now to get back to "fairness." Below you will see what is called a "batten," essentially a long, straight, flexible piece of wood which, when gently bent over the frames of the boat, throws into sharp relief the amount of adjusting and readjusting which must be done to get that coveted "fairness." The bow and stern posts must be angled to match the pitch of the batten as it comes down to meet them and the frames must be raised or lowered until each one just barely kisses the batten as it passes over them. Once this is accomplished you know the curve is gentle and most importantly...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSUqnxA7WLO4rBopORSbhEeKn_-0VtjUR-3I6h6eLegeyYydfT5GGvWWz9OVGHlu-kvYkef1hTUhVKPkd1n3RZ1ZrTW3StOYc_4_3lmt19NtBXjcXGxO5BPA9L_vtgeTOKU_4ydCKrRC8/s1600/batten.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSUqnxA7WLO4rBopORSbhEeKn_-0VtjUR-3I6h6eLegeyYydfT5GGvWWz9OVGHlu-kvYkef1hTUhVKPkd1n3RZ1ZrTW3StOYc_4_3lmt19NtBXjcXGxO5BPA9L_vtgeTOKU_4ydCKrRC8/s320/batten.JPG" width="320" /></a></div>
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...fair!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDN_P_SfmMcBOB3nLunX0mjWIv7Rn1QIpZWz8NOMWc9rK_0xjQIoixP88G8YQoP90jHUFy-gAMr3ylNSHCuPyHwRbV9e6JwfTAEX8gNWoNVyp6p5w71-mAIaMS0nzttrbUyZqEFmS7nQE/s1600/fair.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDN_P_SfmMcBOB3nLunX0mjWIv7Rn1QIpZWz8NOMWc9rK_0xjQIoixP88G8YQoP90jHUFy-gAMr3ylNSHCuPyHwRbV9e6JwfTAEX8gNWoNVyp6p5w71-mAIaMS0nzttrbUyZqEFmS7nQE/s320/fair.JPG" width="320" /></a></div>
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The next step is another big learning opportunity...the "scarf joint." I am excited because once I do that, I will be able to plank the sides and it will start actually looking like a boat! Stay tuned for more to come and wish me luck...</div>
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<br />Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com0tag:blogger.com,1999:blog-2266643419546694069.post-274952757117492852012-05-21T00:18:00.000-07:002012-05-21T22:27:43.418-07:00And so it begins...<br />
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Well, I have taken the leap and gone from cabinetmaker to boat builder. Give me strength...<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM2PVKLr51bYFquZQOQ4BaDvm-fnHt7lQIPgDYKKIiDkImDvnPVP5mVu-rAZ02C6taSvbjYRf2iwb9N7l35x_RNKFdPNi5IS3GzfukYUNUOSODki0xzFnfMC8D8_XzKlvrNFwM41e2N00/s1600/Duck+Punts+sailing%2521.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM2PVKLr51bYFquZQOQ4BaDvm-fnHt7lQIPgDYKKIiDkImDvnPVP5mVu-rAZ02C6taSvbjYRf2iwb9N7l35x_RNKFdPNi5IS3GzfukYUNUOSODki0xzFnfMC8D8_XzKlvrNFwM41e2N00/s320/Duck+Punts+sailing%2521.jpg" width="320" /></a></div>
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This blog will be a random document of my attempt to build a design by John Milgate called the "West Mersea Duck Punt." The Duck Punt is a sailboat just shy of 16' that you lie down in and sail with your feet kicked over the side in water as shallow as a few inches. No keel, no dagger board, no lee board, just a hard chine and a canoe paddle for steering and lateral resistance. Pure, simple, and fun! The boat uses an Optimist rig which is a basic sprit sail with surprising performance, especially in light air which is the limitation in a boat of this design.<br />
I was first introduced to this boat by Dylan Winter's incredible website "<a href="http://www.keepturningleft.co.uk/" target="_blank">Keep Turning Left</a>" and if you have not been to his site, you should go right now and stop wasting time reading my ramblings. He has a whole section describing his experience building and sailing a Duck Punt with lots of videos and the actual plans to build one if you want to share my adventure. There is also a site devoted to these boats at <a href="http://duckpunt.org/">DuckPunt.org</a> which they describe as "Sailing so chilled the sailors lie down." Watching these guys cruise through the marshes in inches of water sealed it for me and I knew I had to build one. My experience with woodworking is much different and has centered around furniture and cabinet making (<a href="http://rustyknorr.com/">RustyKnorr.com</a>) so boat building is completely new and different, and so far really fun! I also have to thank <a href="http://duckpunt.wordpress.com/" target="_blank">Stan Richards</a> in California for his encouragement and advice after building his own Punt recently.<br />
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Things began with needing to find a space to build a boat. After searching for a while, I finally decided to do it out in our courtyard. We live in a converted elementary school/artist community called "<a href="http://dnrstudios.blogspot.com/" target="_blank">Artwood</a>" so using space outside proved to be no problem. This is the space before converting to boat building.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAKQ0lGKrGtP4uP6LJq0uch7AhuBmXymROU0rEqCW-NXUet6O2WRss7c8NfQaS3tNqt3BVaBpnBYHHX70lpaYvRcUTAM_bgXUqyQDdj2jKpiaN5UDDRS-sKrPwMi6hd23d9JPVMOgGj4s/s1600/workspace.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAKQ0lGKrGtP4uP6LJq0uch7AhuBmXymROU0rEqCW-NXUet6O2WRss7c8NfQaS3tNqt3BVaBpnBYHHX70lpaYvRcUTAM_bgXUqyQDdj2jKpiaN5UDDRS-sKrPwMi6hd23d9JPVMOgGj4s/s320/workspace.JPG" width="320" /></a></div>
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Of course a boat builder needs tools to work and I like really nice tools, so...get out the wallet and empty it on the finest. Festool! A new jig saw and a new plunge/track saw. This boat is getting expensive and I haven't even bought any wood yet!!!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijIja4JDRM0qLCDLp_UgltRPKz_EPlx1pyYYuiZAg21vWR1oW-_T0oGRDoMxqfc3KkZV8aYwTj4bm3yIMAKbmgY-HHnrMeeb3VeT-i4d24YUBAz4F2dYGVSBkgd-yxlbYsxQOnq1VWzMU/s1600/Festools.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijIja4JDRM0qLCDLp_UgltRPKz_EPlx1pyYYuiZAg21vWR1oW-_T0oGRDoMxqfc3KkZV8aYwTj4bm3yIMAKbmgY-HHnrMeeb3VeT-i4d24YUBAz4F2dYGVSBkgd-yxlbYsxQOnq1VWzMU/s320/Festools.JPG" width="320" /></a></div>
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What is a sailboat without a sail? The Punt uses a common rig from an Optimist so I ordered one from Intensity Sails. The spars arrived right away as you can see, the sail is a 4 to 6 week wait. Probably fine since I imagine the Punt will take that long to build anyway.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD3ad34_VypBu97a5wEI01oOUmOpMNqtJEQRWJr5usym2oksXH340QbvlQMjV2dkahDBrYDeLT5agyZ7aijc0q757Lzv-sxiAsYly6w1VxP6kl0zfXx0JDKdlWteDeCpQ1uVXAZWgxyCM/s1600/optirig.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD3ad34_VypBu97a5wEI01oOUmOpMNqtJEQRWJr5usym2oksXH340QbvlQMjV2dkahDBrYDeLT5agyZ7aijc0q757Lzv-sxiAsYly6w1VxP6kl0zfXx0JDKdlWteDeCpQ1uVXAZWgxyCM/s320/optirig.JPG" width="240" /></a></div>
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Well, you can't build a boat without wood! I finally went to the big box store and bought 3 16' 2X4's. These will be used to make the jig the Punt is built upon.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqJ5nNW6YlnhjcE40dKwWlrt2d-n-8GCJy1Nf-WWlVGZQC3sHw0KrGkd2tPxF5GyxAWXKJRhJjEPrqAUJRPM6e91-T9Xef2PSXCne7UCejtwvYnwqddec4yx63BDmuvaeIGgSDVjg8vW0/s1600/car.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqJ5nNW6YlnhjcE40dKwWlrt2d-n-8GCJy1Nf-WWlVGZQC3sHw0KrGkd2tPxF5GyxAWXKJRhJjEPrqAUJRPM6e91-T9Xef2PSXCne7UCejtwvYnwqddec4yx63BDmuvaeIGgSDVjg8vW0/s320/car.JPG" width="320" /></a></div>
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Here is the space after cleaning things up enough to have room to work. The miter saw is not in following my "best tools" philosophy but I got it free so I will make do.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwzauDjoabeuoOsnGD5wwVy36UJzVVDmPSm0L743rMjZzBd18ZR7ZQhm8Yx1ADX6SycFzRMgk5Ga8A1zhxcbugYdiVqEfi2UILOkGCxkuXTqVoN9QnAeUOE2YBd0thk17rw2OIMo5Pdcc/s1600/newworkspace.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwzauDjoabeuoOsnGD5wwVy36UJzVVDmPSm0L743rMjZzBd18ZR7ZQhm8Yx1ADX6SycFzRMgk5Ga8A1zhxcbugYdiVqEfi2UILOkGCxkuXTqVoN9QnAeUOE2YBd0thk17rw2OIMo5Pdcc/s320/newworkspace.JPG" width="320" /></a></div>
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Wow, I finally built something! I made the disgusting discovery that 2X4's are not in the least bit straight, even after picking the best in the pile. Hmph! The things you have to learn to accept as a cabinet maker building a boat. <br />
Woe is me.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2zYVb2C2Q712yRozjdcN6mzvBRJHH8a-kYN5b_QowjAbuoWaEhWlkwTcOLq1eG6tirWjOhR2n-xi7ctTzHS2q92APBFhfcoOXs0iA1L_iPD3_ezFR9ENCg7xrqygM_LxGcE8QMBtOxe0/s1600/jig.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2zYVb2C2Q712yRozjdcN6mzvBRJHH8a-kYN5b_QowjAbuoWaEhWlkwTcOLq1eG6tirWjOhR2n-xi7ctTzHS2q92APBFhfcoOXs0iA1L_iPD3_ezFR9ENCg7xrqygM_LxGcE8QMBtOxe0/s320/jig.JPG" width="320" /></a></div>
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Finally! I bought some material that is actually going to be part of the boat! And let me tell you...marine plywood is expen$ive! With the variety of choices available, I decided to use Hydratek. Middle of the price range, durable, and a little heavier. (We'll see if I regret that later.) Below you can see the layout for the frames the boat will be built on. I decided to use the same frames for the building jig as well as for inside the boat. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgarlEPn3gF0AeEeedWiyau1CBMkLRaXSzAbEb6QndUrIB_GQofkOLBZipCyN-Ls2uGmivJpC5EYrINn7CBNqMKruI6HRqhTBsfMQ3-ANwNDns2i9cVuDiRDhC8ToAh9Y3PkPcb7yVPFXU/s1600/framelayout.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgarlEPn3gF0AeEeedWiyau1CBMkLRaXSzAbEb6QndUrIB_GQofkOLBZipCyN-Ls2uGmivJpC5EYrINn7CBNqMKruI6HRqhTBsfMQ3-ANwNDns2i9cVuDiRDhC8ToAh9Y3PkPcb7yVPFXU/s320/framelayout.JPG" width="320" /></a></div>
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Let's cut some plywood and give these new tools some action! Roughing out the frames is the first step. That jig saw is just fantastic!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQl0E8w1cqiRqH20gY-OdVGcjciC1b7TLLCYJu63uUdSdflAWoMy0QjRjF2YdK-V6kkv4tHniMw9jt34q6seBJsgXDaJUneNJlGhG5wi3096GsVhKCFZh4GBALelHetLCQVqNhtrA3IMY/s1600/firstframe.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQl0E8w1cqiRqH20gY-OdVGcjciC1b7TLLCYJu63uUdSdflAWoMy0QjRjF2YdK-V6kkv4tHniMw9jt34q6seBJsgXDaJUneNJlGhG5wi3096GsVhKCFZh4GBALelHetLCQVqNhtrA3IMY/s320/firstframe.JPG" width="320" /></a></div>
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Now we trim them to final size with the track saw. If it is possible to fall in love with a saw, I did.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEho0l244wAsbk3_5V2MQEl5SO5_n264KsY7Ioz699lL0QsEWq3ug3jwxTjWIPlI7UZ7k_p0gTJOhltNkG6BUDrZ4Dh_-vbYyer0au5yJXaW2PgF74Wzp34F8uz0d6TBvOSTsumg_yS_cIU/s1600/frameshaping.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEho0l244wAsbk3_5V2MQEl5SO5_n264KsY7Ioz699lL0QsEWq3ug3jwxTjWIPlI7UZ7k_p0gTJOhltNkG6BUDrZ4Dh_-vbYyer0au5yJXaW2PgF74Wzp34F8uz0d6TBvOSTsumg_yS_cIU/s320/frameshaping.JPG" width="320" /></a></div>
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The next step after moving the jig onto saw horses is to level it with a laser level. Then, attach the frames to the jig, making sure they are dead level, square, and in perfect reference to each other. This is harder than it sounds with 2X4's that are not straight. Success was achieved with that laser which is turning out to be a very useful tool.</div>
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I am really having fun teaching myself how to be a boat builder. More to come, stay tuned!</div>
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</div>Rusty Knorrhttp://www.blogger.com/profile/01237295574950108531noreply@blogger.com2