Laminated floors (2006)

Next the laminated floors were made. Meranti strips 8mm thick were clamped into position against the stringers and backbone with glue between the strips but not against stringers and backbone. Each floor was done in three stages. After each was cured, the floors were removed from the hull, shaped and cleaned. Spacers that are needed between the floors and backbone were fitted and doublers were added on center line. The floors were then glued and screwed to all structures they touched on the hull.

Laminating on the hull setup

Laminate clamped onto stringers and backbone to get shape

Floors removed and ready for cleanup and finishing

Floors glued to stingers and backbone (note spacers at backbone)

Doublers at front face of floors (to replace wood lost as result of drilling for keelbolts)

The Stem (bow)

The next stage in the building process was the lamination and installation of the stem. The stem piece was laminated from two 100x100 mm Meranti (Lauan, Philippine Mahogany) planks. That was the easy part! Next the stem had to be set up on center line and at the proper angle and distance from bulkhead A.  The backbone then had to be connected. All had to come together so that the waterline, center line and final planking dimensions agreed to the plan scantling. The stem and backbone were then glued in position complete with knee. The backbone and transom were also connected with a knee. The knees where constructed out of 4 layers of 12 mm plywood. The stem was then planed to its final shape. This was done using temporary stringers as guidelines. The stem took 36 man-hours. In total I have spent 527 man-hours up to this stage.

Using a Spanish windlass to bring the backbone and stem together

Measurements for stem in relation to waterline

Stem center line and waterline in position

Knee glued in position and shaping of the stem

Using the stringers as guidelines to shape the stem

Saw marks as guides for planing

Planed to shape

Sheer clamps and stringers (2006)

The sheer clamps are fairly heavy pieces made from 3 meter  x x mm planks scarfed into the required total lengths (about 11 meters). Before gluing and screwing to the clamps on the bulkheads, they were roughly shaped by planing angles on the sides determined by the angle on the bulkheads. Fitting was quite a job. I started in the middle working towards the stern and bow. As suggested in the building guidelines, I did the fitting in tandem on both sides to prevent the setup being pulled out of symmetry.
The stringers were made from 22 x 45 strips of 2,7 meter lengths scarfed into the required total lengths. They fitted snug into the stringer slots on the bulkheads and some slots had to be adjusted to the angle of the stringers with a rasp. The forward ends of the stringer had to be morticed into the stem. At the tangent stringers (where the flat side skin panels and the round part of the skin on the chine comes together) plywood doublers were attached to the stringers to increase the surface area for gluing of the skin panels. Total time spent on the stringers and sheer clamps; 169 man hours.

Shear clamp

Stringer fitted

Stringers morticed into stem

Plywood doublers at the tangent stringers

Backbone (2006)

By March 2006 it was time to start with the framing. First of all the backbone had to be scarfed and glued before installation. One of the lessons learned by now was that one must not use epoxy that is thickened too much. This will produce a so called "dry joint" and will not produce a strong bond into the wood. Furthermore, once clamped, be sure to leave the clamps on for at least 48 hours. And if the clamps are to be removed before 7 days, do not place the joint under stress for at least 7 days. The epoxy reaches maximum strength only after 7 days.
The backbone, from the raw wood to finished and installed took 20 man-hours.

Scarfed and ready for the glue

Clamping while epoxy is setting.

Tapering the backbone to fit into the bulkhead slots.

Backbone glued onto the bulkheads.

Setting up the bulkheads (2006)

After completion of all the bulkheads, it was time to set them up on a strongback. I started with the construction of the strongback during January 2006. It was constructed out of pine rafters fixed to pine posts cemented in concrete. The strongback must provide a stable platform onto which the bulkheads can be set up in their respective positions, plump and perpendicular to each other. At the same time a tarpaulin roof was made to protect all future building from sun and rain. Luckily the construction area was fairly well protected from wind.
I started with bulkhead A. At this stage one of those laser levels is a handy piece of equipment to have. When mounted on a tripod one can easily line up all bulkheads with the level. A plump line was used to ensure each was vertically set up according to the center-line. It took 90 man hours to build the strongback and set up all the bulkheads.

PS, Through time I have experienced the difficulties, or should I rather say, the problems one encounters when building a boat outside. Without a proper enclosure one is always exposed to the elements. It being too hot or too cold, windy and wet, or just plain unpleasant. Furthermore, epoxy is sensitive to high and low temperatures and during the curing process does not like moisture. Water discolours wood and must be kept away from the untreated panels. These are all factors that influence the speed of the building process.

The strongback.

Bulkhead A installed.

Bulkhead B. Note the plump line on center-line.

Bulkhead C from a different view.

Note center-line.

Two more to go.