Back on track...

Last Saturday's enthusiasm over the assembled hull was tempered a bit by Sunday's realization that the dry-fit hull would have to be taken apart...

The bottom panels had not yet been glued together. I could have assembled them at the apartment - with no way to transport the bottom to the shed. I could assemble the panels at the shed - but there was no room with the assemble hull taking up space. The only legitimate option was to take the hull apart, glue the bottom panels, and then reassemble and glue the hull. I took the hull apart last Sunday.

I made excellent progress on the box boom - as described earlier. The boom needs some finishing work, but the structure is done.

This afternoon I was able to set up a clamping arrangement for gluing the bottom panels together. Two butt straps were fabricated and everything was fit together to make sure I had the sequence down. I clamped two 1x3 boards together to use as a caul. To reduce any bowing of the caul I set it up on edge. Epoxy squeezed out from the edges of the butt straps when the clamps were tightened so I believe there was adequate clamping pressure along the entire length of the join.



The seam should be cured enough tomorrow to be able to move the bottom out of the way for reassembling the hull.

How Light is Too Light?

I took the afternoon off and took care of last minute Christmas shopping on the way home. At home I figured out what I wanted to accomplish at the shed and what time I needed to be back home to get ready for tonight.

At the shed, I removed the clamps on the boom - and found several largish gaps on the top side of the boom between the second side and the timber. Apparently I did not make sure I had even pressure when I clamped the second side yesterday. The gaps can be filled with epoxy but it is a lesson learned for the next one.



I trimmed away the excess ply from the sides with the pull saw. The block plane worked well to trim the sides down to the timbers. I mixed up a short batch of thickened epoxy and took a few minutes to fill in those gaps. The end caps need to be installed - as is apparent from the photo.

The boom weighed 2.63kg (5.8 pounds) which is much lighter than anyone else has reported. Then I measured the distance from the floor to the top edge of the boom supported on either end by a saw horse. I hung 20 pounds from the mid-point of the boom and measured from the floor to the top edge of the boom. The difference was 2cm. This is less deflection than anyone else is reporting.

I believe this box boom is lighter and stiffer than any of the solid wood spars built to date.

I am quite pleased with these results.

Tonight, I spent time with family and friends and enjoyed the spirit of the Christmas season.

A Change of Plans

We planned to glue the hull together today. However, two things today are pushing the glue-up until Saturday. Scott called to tell me he had been up most of the night not feeling well, didn't get to bed until nearly 6:00 and he was exhausted. I told him to get some rest and we could glue the hull next weekend because...

I forgot (sorta) about the bottom panel... The bottom panel is still in two pieces and, until this afternoon, was still at the apartment. I realized that even if I could glue the two pieces together here, I'd have a difficult time moving the nearly 16' long bottom to the shed. But, I also realized that with the boat put together there is no room in the shed to coat the panels and glue them together.

So, it was a good thing we didn't glue the boat together today...

Instead, I took the boat apart (much easier than putting it together) and then worked on the box boom.

Here's a shot along the sheer line with a temporary gunwale in place.



Even though temporary and only clamped on, those gunwales stiffened up the boat and smoothed out the sheer line.

And here is a picture of the top timber and one side of the box boom ready to be glued.



It took 8 clamps to set it up but 15 clamps to make sure there were no gaps along the join.

Tomorrow I will glue the bottom timber in place and begin work on the bottom panels (coating with epoxy).

So not being able to glue the boat today turned out to be a good thing.

An Even Better Day!

Today was one of those milestone days. One small step for boat building, one giant step for me...

My pile of wood and parts became a hull today! I now have what I can honestly say is a Goat Island Skiff. Oh sure, today was just a dry-fit (glue-up tomorrow), and the bottom isn't ready to go on (so it won't float as a boat just yet), but what I've got sitting at my daughter's house is recognizable as a Goat Island Skiff!

Things did not go as smoothly as I would have liked. I do not know how this boat could be built by one person working alone. My oldest son, Scott, was a huge help today - and we could have used at least one more helper.

The sequence went something like this:

Checked yesterday's glue-up of the chine logs - they seemed fine.

Set things up with the side panels on the correct sides, stem, dry-wall screws with pads, and driver. One thing we could have done differently - and I may change things around tomorrow - is to have the panels turned 180* (so the "pointy" end is at the front of the space where the double doors are located. May not make any difference but it might.)

Screwed the starboard side panel to the stem (this was actually the absolutely easiest part of the process).

Tried to screw the port side panel to the stem... wouldn't match up. We had to rearrange the space so we could "open up" the side panels. Got it figured out



Bulkhead 1 did not fit. We rearranged things again so we could manipulate the side panels, we used a strap to pull the sides in, we wrestled it and muscled it , we tried using a bar clamp to pull in the bottom edges of the side panels, but nothing we did worked. I was discouraged - to the point of thinking about walking away to face it tomorrow. Scott suggested using a trucker's hitch as a come-along but we didn't have a way to attach the line to the panels.

We went to the hardware store to buy an eye screw, a hook and some small line.

Back at the shed, we set things up but the line (strong string really) snapped. I got a length of 1/4" Stay-Set from the back of the Jeep. Scott set up the trucker's hitch come-along - and it worked! Bulkhead 1 was fit (needs some trimming for a better fit).

We moved the eye and hook, set up the come-along, and had an easier time with Bulkheads 2 and 3.



Moved the hardware again and set up. Bulkhead 4 went into place - but I ran out of dry-wall screw pads. I used a 2-1/2" deck screw for the last screw in Bulkhead 4.

By this time we wanted to complete the task and install the transom... so we did. Using more of those 2-1/2" screws we got the transom in place. We didn't snug the transom in place but even so, the diagonals from BH2 to the transom are within 5mm.





So, there it is, my Goat Island Skiff hull actually looking like a Goat Island Skiff!

Tomorrow I'll trim some of the bevels for a better fit and then we'll glue it all together! I'll also get better pictures to show off this lovely shape.

Seeing these photos reminds me I forgot to clamp the gunwales to the sheer. I will do that tomorrow.

I am very pleased with today's progress and results. I have a boat HULL!

A Fun Day

Well, I had a fun day!

This morning I went to TAP Plastics to pick up a different epoxy filler material. I have been using micro-balloons all along but decided I'd change fillers for more strength. After discussing my project with the clerk, I bought a container of chopped fiberglass filler.

At the shed I first checked on the glued up box boom timber. Using a chisel and the block plane I dressed the scarf joins and decided I had done a pretty good job with this one!

Set up for gluing the chine-logs went pretty well. I made a gauge for setting the 10mm overlap using a craft stick cut square and drawing a line at 10mm from the end. Placing the chine-log on top of the side panel I could set the overlap by holding the gauge against the edge of the side panel, setting the chine-log at the 10mm line, and clamping or screwing (as needed) the chine-log in place. Once the chine-log was in place I penciled a reference line on the hull panel. I repeated this process for both sides.

The spring clamps worked very well but I realized I didn't have enough! No surprise there. I made a quick run to the big box store for additional clamps and decided to renew my practice of buying two clamps each time I go into that store! At a buck apiece they are quite affordable. The ones I bought today have a much stronger spring (and green grips instead of blue) than the ones I bought earlier this year.

Not knowing how much epoxy to mix up I went conservative and mixed a 3 ounce (2 resin 1 hardener) batch, figuring it would coat both surfaces (chine-log and side panel) for one side with enough left to thicken and finish the one side.

I coated both surfaces and thickened the remaining epoxy. I've never worked with chopped fiberglass so it was a new adventure. I mixed in the filler until I had a consistency that seemed "right." That batch coated about half of the side panel so I quickly mixed up another, smaller, batch.

The chine-log went on pretty smoothly. Using 4 screws and 11 clamps I was able to seat the chine-log against the hull panel and eliminate all gaps between the two surfaces.

There was one change in this process for the second side. After coating the mating surfaces with straight epoxy, I used a combination of micro-balloons and chopped glass to thicken the epoxy. This gave me a "better" consistency and it was easier to spread on the side panel (I applied the thickened epoxy to only one of the mating surfaces).

I had planned to begin assembly of the box boom today but decided to glue up the second timber instead.

Here's how I left things this afternoon:



Yes, the side panels are stacked. The gox boom timber is there on the right.

Tomorrow's plan is to dry-fit the hull!

Early Mid-Week Notes

I've cut out the plywood blanks for the box boom (I keep wanting to say, boom box!) and glued them to length using butt straps. The timbers for the top and bottom are cut out and ready for the scarf joins to be cut. I'll begin those tomorrow. I should be able to assemble the box boom this weekend and then figure out how to test its stiffness.

The chine-logs do need a bit more sanding but - and this is an important but - I should glue the chine-logs to the hull sides Thursday evening or Friday morning.

That means everything I need to dry-fit the hull will be ready on Saturday. I could have a GIS hull this weekend!

Hollow Box Boom

The sail rig for the Goat Island Skiff is undergoing further development and improvement (well, that is what we're all hoping for...). The discussion of this can be found at:

GIS Spars

While others are experimenting with different sized solid yards and booms, Mik wondered about how a hollow box boom would work. I asked Mik for dimensions and volunteered to make a hollow box boom. This is a side project to do while waiting for epoxy to cure (or be delivered!) and is not a diversion away from the Goat itself.

The basic design for the boom:

• Overall Dimensions: 45mm wide, 70mm deep, 3660mm long
• Four pieces
  • 2 6mm Plywood Sides
  • 2 12mmx33mm Top and Bottom Timbers
• Tapered in profile to 45mm x 45mm at each end
• Corners radiused to match the plywood

Butt strap joins will be used on the plywood to obtain the 3660mm length. The top and bottom timbers will be scarfed.

I cut the plywood pieces today and laid out the cut lines for the timbers. I will cut the timbers and make the scarf cuts early this week. Once the epoxy supply is replenished I will glue the four pieces together and assemble the boom.

Being involved with the development of the rig is pretty exciting!

Getting Closer...

The second side of the hull is now in one piece! The backside of the seam - what is actually the outside of the hull - is not as nicely glued as the first set, but the joint is very strong (nothing fell apart while moving it about the work space!). The parchment paper and packing tape worked their magic again minimizing the epoxy spread and flattening/smoothing the epoxy on that backside. I am pleased.

I worked a bit cleaning up and dressing the chine-logs. Using the block plane to fair the edges of the scarf joins and the ROS to further smooth the joins and remove nearly all of the primer. Remember, the chine-logs came from primered finger-joined spruce facia, so that primer had to be removed.

As I was working on the chine-logs, it occurred to me the hull sides will not be quite so loosey-goosey floppy once those chine-logs are installed. That should make working the sides a bit easier than I imagined yesterday.

My DuckWorks order (new epoxy) should be delivered tomorrow - which means I won't get it until Tuesday. I just can't get to the apartment manager's office before she closes but I can arrange to get it on Tuesday. That still gives me a couple three days to figure out the installation of the chine-logs and be ready for the dry-fit of the hull on Saturday!

Good Results!

When I unclamped yesterday's glue-up of two side panels, I wasn't too sure what I would find. But nothing fell apart... the seam between the two panels is very uniform... there are no huge spreads of epoxy needing a great deal of sanding to bring under control... I am greatly relieved and genuinely pleased with the results.

I made a couple of changes for today's glue-up of the second hull side. I switched two of the saw horses so one of the wider ones was in the middle position. This arrangement provides better clamping angles. I also used a combination of 1x4s for the caul/spacer block to spread the clamping pressure over more of the strap. This was necessary because the forward panel developed a bow over the last couple of days. From what I could tell, the bow was flattened by the clamping pressure. The epoxy squeeze-out was uniform around the perimeter of the strap.



So, I wait for the epoxy to cure... Tomorrow I'll see how I did today.

Anatomy of Gluing the Side Panels

Today's gluing of the side panels went pretty smoothly. I am sure the test run I did at the apartment a few weeks ago helped, as did the test run today before I mixed up the epoxy. The following pictures were taken during the test fit this morning as I set up to glue the side panels together. Fortunately, I remembered to put parchment paper down on the masonite base before actually gluing the panels together! Otherwise I would have had a mess of a problem tomorrow!

Step 1: Lay the recently glued up full-length chine-logs across three saw horse to support the panels.



Step 2: Support blocks so the side panels do not sag when clamped.



Step 3: A masonite base to support the join while the epoxy sets up.



Step 4: Side panels in place.



Step 5: Butt strap with pin-nails to keep the strap from slipping around on the epoxy.



Step 6: Spacer block to raise the clamp block above the pin-nails.



Step 7: Clamp block - a piece of 2x4



Step 8: Clamped in place.



I took everything apart, put parchment paper on the masonite base, mixed up some epoxy and applied unthickened epoxy to both the side panels and the butt strap. Then I added filler to the epoxy, got the consistency I wanted, applied it to the butt strap and the panels (making sure I covered the edges), and clamped everything together. The panels didn't sag when clamped, the strap stayed put, and epoxy squeezed out from under the strap.

All in all it went pretty well. I suspect tomorrow's glue set-up will take less time and go smoother.

I am very pleased with today's efforts.

Finally... Real Progress!

Okay, so it still does not look like a boat but the project took a huge step forward today.

I glued up two side panels! Since I really only had room on the horses to glue up one side, the other side will wait until tomorrow.

But, today's work does represent a major step forward!

Fun Stuff

I enjoyed yesterday's exercise with Honduran mahogany.

I went shopping at WoodCraft - something usually limited to "window shopping." But they have a decent selection of hardwoods in convenient sizes so I went to see what I might find. I needed some hardwood for the top piece of transom framing, the knees, and breasthook.

What I found was a decent piece of Honduran mahogany, and with the $10 store coupon it wasn't going to hurt the wallet too much.

Here is the transom top frame - cut, shaped and glued to the transom.



I really enjoyed working with this material. It cuts and planes nicely. As a bonus, the color is a pretty close match to the cedar used in the other framing.

The cut-off from the board is enough for the knees and breasthook. I won't cut those just yet but I am looking forward to that stage of the project.



Okay, so it is just a board, a piece of wood... but it is a piece of wood... and a very nice piece of wood at that!

This boatbuilding has introduced me to new (to me) tools and materials, and taught me new skills. And after all this, I'll have a boat!

That dry fit of the hull is getting closer... and the glue-up won't be far behind...

Moved...

This morning I took boat parts, supplies, tools, and equipment over to my daughter's house.



The space is cozy but it is great to be set up and working on the boat here.



To get things started, I glued up the chine-logs.



The stem and bulkheads made the trip this morning but hull panels are still at the apartment. I'll take those over later today or tomorrow and get them glued this week.

While all these parts don't look much like a boat yet, that phase of construction is right around the corner.

A Step In the Right Direction...

The Jeep moved under its own power today for the first time since mid-July...

A friend took me up to Sears this morning to buy a battery. The Jeep fired right up with the new battery. I let the engine run for about 30 minutes or so to warm it up. It didn't stall, shut down or otherwise quit, so I crossed my fingers, put it in drive and drove to the other side of the complex (I've been squatting in another apartment's designated parking space all this time).

A quick rinse with the hose only moved the nearly 5 months' accumulation of dust and dirt around. I'll take it for a wash and an oil change later.

For now I am excited to have a working vehicle again!