David Jost's Boatbuilding Page
Step one is to get some great plywood. I found some 6 ply 1/2"
marine grade plywood from Downes and Reader in Stoughton. MA.
Compared to the stuff I had used in Diablo, this was a dream to
Step 1 - Layout the frames and transom. I built the transom from
4 layers of 1/2" with a mahogany frame inset. My first attempt
left the transom too small. (wish I had a photo of this), and I
paid for it in several additional sheets of plywood as I approached the
finishing stages as I did not have enough sheets to complete the
journey due to this small error. It was a $120 mistake.
Measure several times prior to cutting these pieces. The
stem is a pretty straightforward project, however I lack a bandsaw.
Therefore, I did it by hand. Time consuming, but doable.
Step 2 - Layout the sides. I used Payson style glass but
joints. They are as strong as the ply itself and took to bending
quite easily. (once again, I should have took a photo, but went
right to set up as the year was drawing close with the weather window.
Step 3 - Carefully align the frames on the frame marks clearly
visible on the plans. A little bit off here, and it makes fitting
and cutting everything else a bear. Notice I am off by a 32nd on
a inch. It makes a difference. I did brace the sides to the
wooden structure of the garage to help with this.
Step 4 . - The bottom
The bottom is supported by temporary 2X4's and a couple of 2X6's this
makes an easier platform to work on which to align things. Notice
how the lawnmower and tablesaw are outside temporarily. Watch for
the appearance of the snowblower shortly.
After the bottom is on, it is time to use the glass mat tape to join
the panels permanently. I hollow out a shallow trench to lay the
glass into with a 7" disk grinder otherwise nicknamed the wood eraser.
The glass is set in epoxy and then a layer of wax paper is pressed into
it with a wide bladed taping knife. This comes out baby bottom
smooth and is easy to fair and smooth later on.
Ok, we are now ready to clean up and get it out for glassing.
Yes, It is New England and we do ski here despite Global Warming.