Skin On Frame For Me!

Discussion in 'Boat and Accessory Building' started by LAM, Dec 28, 2012.

  1. LAM

    LAM Paddler

    Joined:
    Dec 28, 2012
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    Hello! First time poster here. I am excited to share my build with you all. My husband posted his SOF build on this forum a year or so ago (Paddlesores). He will be assisting me with my SOF but I will try to do as much of it as possible as I truly want it to be "my build". It will be 16' long and 19.5" wide. I started on December 25 and prepared my Story Pole.



    December 26 I planed the rough lumber (yellow cedar) for the gunwales. December 28th I cut the cedar to size for the gunwales. Then jointed to clean up the edges and get an overall width of 2 5/8" wide.

    I then cut the gunwales to length (14' 8") on the chop saw. Next step was determine and mark the top and the bow and stern of the gunwales. Then marked the "Gunwale Midpoint". Then using the Story Pole I marked the deck beam locations and then marked the rib locations.


    Now I am going to go out to mortise the bottom of the gunwales for the ribs.

    Lila
     

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  2. woodman

    woodman Paddler

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    Location:
    Bates City Mo.
    It is a good thing to see Lady's building their own boats...have fun.
     
  3. west_coast_russ

    west_coast_russ Paddler

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    Location:
    Victoria
    Keep the pics coming - look forward to seeing the progress.
     
  4. LAM

    LAM Paddler

    Joined:
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    Last night I routed out the rib mortises - first time ever using a plunge router. I am pleased to say that it went very well.


    Today I layed out the gunwale hollows.


    Then I started the tedious job of cleaning up and squaring off the rib mortices using a chisel. After the first few I kinda got the hang of it and hopefully by tomorrow evening I should have all of them (46!) done.

    Lila
     

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  5. Wolfman

    Wolfman New Member

    Joined:
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    Location:
    Everett WA
    Keep up the posting and photos! I look forward to seeing the kayak all come together.


    Wolfman
     
  6. LAM

    LAM Paddler

    Joined:
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    All of the mortises have now been squared up. It took a total of 3 hours to do this, but I broke it down over two days, so it wasn't so bad.



    Today I cut the Stern triangle using a hand saw and then a hand planer and giving it a final clean up with a hand sander.



    Building a kayak is a big enough learning curve on it's own, but add to that learning how to use tools properly and efficiently! But, I am on day 6 and still very excited to get out to the shop to keep at it.



    I think it turned out pretty good.... So tomorrow I can do the Bow!

    Happy New Year to you all!

    Lila
     

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  7. Roy222

    Roy222 Paddler

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    Happy New Year back to your all!
    Very nice craftsmanship.
    You shop is really clean. My shop is never that clean, even after a clean up.
    Keep the photos coming, I think this will be a very informative build.

    Roy
     
  8. LAM

    LAM Paddler

    Joined:
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    Thanks for the encouragment! I am happy to hear that people want to see my pictures, so I will keep them coming.

    On New Years Day I finished cutting out the bow triangle then planed and sanded it. Then a final check for square.




    Next I sanded the rest of the gunwale just to make it nice and, as the husband says, "It never hurts". Then I started kerfing the gunwales.



    This will make removing the excess wood easier and will help in not taking off more wood than I should when I shape the gunwale hollow.
    I was very careful to keep checking the other side of the gunwale to ensure that I was not cutting past my marks.

    Next step is to remove the excess wood with a chisel.

    Lila
     

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  9. LAM

    LAM Paddler

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    Back at it tonight. I spent 2 hours chiseling away the excess wood. It was a bit intimidating using the chisel. I had to make sure I wasn't going too deep. Got close to my lines a few times.... :shock:



    You can start to see the gunwale take shape here.



    Tomorrow I will plane down the gunwales. I am a bit freaked out about this part as I have to keep the curved shape here and I haven't quite mastered the hand plane. Wish me luck!

    Lila
     

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  10. LAM

    LAM Paddler

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    Last night I spent almost 2 hours with the hand plane shaping the hollows then gave it a quick sanding. I was pretty apprehensive about taking too much wood off but in the end I think it went pretty good.



    Today I will get started on sawing the gunwale into 2 pieces. I am a little concerned as other times I've used the hand saw I found that my bottom-side cut was veering off to the right. There will be no room for that type of error with this next step.

    Lila
     

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  11. woodman

    woodman Paddler

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    Location:
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    This is the time I would wheel the table saw out put a 1/16'' cerf blade on and a feather board to keep the pc. pushed up against the fence and have some in feed and out feed suports...
     
  12. LAM

    LAM Paddler

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    Good idea about about using the table saw with the feather board Woodman. That's the way we went. I was not at all confident that I would be able to do this as I have never used a table saw so I had my husband do this step for me. At this point I did not want to take any chances. There is not a lot of room for error here. And I like all my fingers.

    Once the cut on the top side was done we turned it over and made a pass on the bottom side.

    I then used the hand saw to cut what the table saw missed.


    Then I put it through the planer a few times until it was at the final thickness.

    I then gave it a sanding just to make it nice and smooth. Next step was to measure the deck beam locations on one gunwale. I moved one deck beam location back about 1.5 inches as it was pretty close to a rib mortise. I clamped the two gunwales together and transferred the markings onto the second gunwale.


    Next step is to do the mortises for the deck beams.
     

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  13. LAM

    LAM Paddler

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    Yesterday I had 10 minutes of instruction from Doug on how to drill the holes for the deck beam mortises. Then I set to work. Using a jig that Doug had used on his first SOF boat I started to drill. It really took me awhile to get the hang of the clamps... I dropped them a lot. So each deck beam drilled was a chore.


    The first set was bad....

    The second set pretty good....

    Then back to bad...

    And so it went until I had one gunwale done. It took 1 hour 40 minutes. I started to feel pretty comfortable with the clamps towards the end and sort of figured out what I was doing. Got back out tonight to drill out the second gunwale. It went much easier and quicker tonight. I am happy to say I have almost mastered the clamp.



    Only took me one hour tonight to do the second gunwale. Next step is to chisel out the mortises and square them up.

    Lila
     

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  14. mick_allen

    mick_allen Paddler & Moderator

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    Nobody SEES those kind of 'misjudgements' in any other build! Heck, yr showing us what to do. Drilling jigs? wow.

    Anyway - nice build.
    What criteria did you use to drop the gunwale heights at the pinches? Are you going to glue onto the bottom of the gunwales what you chopped off the top to retain visual and structural consistency, heh heh? What'll the critters inside say? (but don't answer, it's a silly question as all the good ones have been answered by your clear progress.)
     
  15. LAM

    LAM Paddler

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    Thanks for the kind comments Mick.
    Yesterday I prepped the deck beam mortises for chiselling by penciling in the rectangular shape of the final mortise.



    Then I set up with a backer board and a jug to help keep the chisel at a 17 degree angle as I removed excess wood.


    It was very important to keep the chisel at the correct angle so as not to gouge out on the wrong side of the morise.


    I got both sides of each mortise on one gunwale done. After the next gunwale is done I will square off the rounded edges of the mortises.

    Lila
     

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  16. LAM

    LAM Paddler

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    Learning curves! I realized as I was chiseling the mortise corners that I should have done that step while I was chiseling the front and back edges. I had to re-clamp the backing board and the jig every couple of mortises. I could have saved myself some time by doing both while it was all set up the first time. I was also told by my instructor husband that "next time we build SOF's maybe we'll buy the mortise drill bit for the drill press".... HU? Oh, well, when I am paddling away this summer I can take comfort in the fact that I took no short cuts.

    My next step was to file the mortises and fit them for the deck beam tenons. Using the file I was able to clean them up and size them almost perfectly. There are two that are a bit sloppy. I can live with that. After a few of them you get the "feel" and it gets a bit easier to file. But my fingers are pretty sore tonight.



    I used a mock tenon the exact size of a deck beam tenon for a perfect fit.

    Tomorrow I can start on the second gunwale. It should be quicker now that I know some of the tricks.

    Lila
     

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  17. LAM

    LAM Paddler

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    Having completed the deck beam mortises on both gunwales it was time to bevel them. Using a marking rule on the top and handmade guide for the side I marked where I will be planing. The idea is to plane the top of the gunwale at a 17 degree angle so that the inside edges don't poke a crease into the skin on the deck of your kayak.



    I then did a practice run with some scrap wood just to get a feel for the angle that I was trying to shape.




    I used a file to clean up the beveled edges and to smooth it out.

    My goal this weekend was to get the building forms made and in place so that I could get the first glimpse of my kayak. It was hard not to rush through the last job as I have been looking forward to this next step. After measuring and marking the plywood I was ready to use the band saw for the first time.


    My husband cut the two end forms for me while he was doing the ones for his kayak.

    Trying it on for size! Fits pretty good.

    I made the forward and aft spreaders and used the drill press for the first time.





    I must say that this is a pretty exciting time, when you get to see what shape your kayak will have. It looks so tiny! I can't wait to finish and paddle.
    I have 34 hours of time into this build so far.

    Lila
     

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  18. BigandSmall

    BigandSmall Paddler

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    Location:
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    Looks like a good fit. Great build thread so far, thanks for posting it.
     
  19. LAM

    LAM Paddler

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    Thanks for the comments BigandSmall. It must be tough on your wife with her new pretty kayak and all the water frozen around her! I like the color she chose. I have thought a lot about the color of mine but I like so many it is going to be a difficult decision.

    Today I beveled the gunwale tips on the bow and stern. This is what they looked like to start:


    I used the hand saw and with my husband holding the gunwales tight for me I ran the saw inbetween the gunwales. At this point I was not actually "sawing" but running the saw through one pass at a time until enough wood had been removed to bring the tips of the gunwales together.


    After that was done it was time to check to make sure that the frame is good and straight. I measured and marked 1/2 way points on the forward and aft spreaders and on the middle form. Then I measured again..... I used a string stuck between the gunwales at the stern and then ran it up the centre and stuck it into the gunwales at the bow. Then using the "eyeball" method I checked to see that it all lined up.



    I am out by 1/16th of an inch at the front spreader, but I am told that this is an acceptable amount.

    Next step is to machine the deck beams to rough dimensions. So exciting!!

    Lila
     

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  20. LAM

    LAM Paddler

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    Last few days have been spent machining the wood for the deck beams. After planing and squaring on the jointer I cut the deck beams to length.

    Carefully marking the deck beam at the inside lines on the correct side of the mortises


    I got them all cut to length using the chop saw


    The two arched deck beams....

    I got a new saw from Lee Valley this week for sawing the tenons. My sawing skills are not great, so I spent some time out in the shop practicing.

    My cuts started out pretty good but soon would veer way off . I could not stay on the line. Doug was giving me lots of tips but I just wasn't getting anywhere. So after a few more practice runs I finally found my problem. I was applying too much force. When I relaxed my grip and the let the saw do the work my lines got much better. Still need a bit more practice but there is noticable difference. I was also given a book to read and it was very helpful.



    Tomorrow I will cut the deck beams to the correct width.

    Lila
     

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