Category Archives: Caledonia Yawl

Gluing the third strake scarfs

I’m still feeling sick today, I was supposed to go cross country skiing today but my body would not have enjoyed it much. So I’m back in the boat shed.
My hot box worked well and the epoxy seems to have set well on the garboard scarfs.
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There was just a little squeeze out that was easy to sand smooth. This certainly builds confidence as I now know my procedures seem to work well. Six more pairs of strakes to go or twenty four more scarfs to glue.

Ian Outghtred’s instructions say to glue the scarfs for the second strake as you are laying them down on the garboards as their is quite a lot of twist at the forefoot of the strakes.
So I’m leaving #2 for now and moving on to number 3 strakes.

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There’s have quite a bit more curve than the garboards.

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I coated the scarfs with clear epoxy to let it soak in the fibers before adding a bonding filler to the epoxy and applying more.
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Some squeeze out lets me know that there are no voids.
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I then clamped them down with a board and a few drywall screws. IMG_8893.JPG

Then my hot box goes back into action.IMG_8894.JPG

Finally gluing the garboard scarfs

Today despite a nasty cold that was keeping me from thinking straight for the last couple days I managed to get out of the house.

As it is winter and my West System hardener 205 is recommended to be used above 4 degrees Celsius I needed to devise a portable hot box to help keep the temperature slightly warmer and ensure that the epoxy gets a chance to kick. I came up with a design that should accommodate most of the glueing of scarfs, the laminating of the stems, centreboard and rudder.

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I built a 32″x60″ frame wrapped in foil backed bubble wrap.

The scarfs once glued and covered by wax paper I clamped down with a block of plywood and some screws. We’ll see how it set tomorrow.
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Then with a 75w bulb as the heat source mounted inside I placed the hot box over the glued scarfs to set overnight. The access hole just gets covered by a piece of plywood.
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With some luck it will set nicely and I’ll be able to repeat the process for the other six pairs of strakes.

Starting to glue up the scarfs

Today I put down two sheets of plywood on the strongback to create the flat surface I will use to glue up the scarfs for each strake of the boat.
There are 26 scarfs to glue and on this platform I easily can do two strakes at a time. So as long as it does not get too cold (my shed is dry but not heated) It should take me seven days to glue up all the strakes.

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To properly glue the scarfs it is necessary to line them up using a string guide provided by Hews & co.

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The platform also becomes a great space to lay out Ian Oughtred’s plans.

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Finishing the Strongback

After nearly a month of rotating colds, strep throat and mor colds affecting my family as well as a couple weekends with cross country running races at Jericho I finally found myself with a day in the boat shed to work on my Caledonia yawl project.
As Patrice has some wood in the shed from the house renovation in the way I spent half my time building shelving for the wood and for my glued strakes once they are done.

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My plan then is to use the Strongback as a platform to glue up all the strake scarfs. Then i will tackle the bow and stern stem laminations.
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Once I’ve completed those two jobs I’ll be ready to put up the station Molds.

Final site preparation

This weekend we were fortunate to have a beautiful dry fall Saturday I escaped briefly to buy the materials for the gutters of the shed.

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On Sunday I had a solid five hour stretch of the afternoon to finish all the parts of the shed (gutters, wall tarps and wood storage)

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And finally sort all the pre-cut boat pieces in preparation for the first step.

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Boat shed day two

Today was a nice warm front ahead of an ominous rain system barrelling down on Vancouver.
I felt the pressure of getting the roof up today.
Working alone I managed to finish the walls and clear out the extra wood and off cuts that were against the fence.

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All the trusses were ready and the trick was to put it all up on my own.

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With a few braces I managed fairly well, but I was quite happy to see Patrice arrive at four and in the last hour we got all the trusses and. Strapping down. Just as it started to rain I got three of the corrugated roof sheets up. So I’m one quarter of the way towards having a dry boat shed.

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Now the only thing I’m missing is a couple gutters to keep the people passing by dry.

Building the boat shed

With my front yard only 25″ wide and my neighbour’s house surrounded in scaffolding; I was not able to set up shop in front of the house.
Fortunately my friend Patrice ha been bitten by the same bug as me and has offered up the slab in his back yard to build a shed.

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We live 5 blocks apart so it is close, but also far enough that when I’m working on the boat I won’t have the usual family distractions and I’ll be able hopefully to do several solid hours of work at a time.

Today it was a late start at three pm but I had bought all the lumber two weeks ago so progress was quick. In two hours I got all the trusses done as well as two of the four ten foot walls.

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Originally i though about using a metal framed tarp shelter which would have been much faster but may not have fit well due to a few issues with the site and the tarp sheds are less flexible than building your own.

Picking up the Pieces

This friday Tania and I went down to Port Townsend to pick up the sheets of marine plywood machined by Turn Point Designs. The boat plans I purchased were designed by hand by Ian Oughtred on a drafting table. But Jordan Boats in the UK went through the trouble of licensing the plans and digitizing them to develop a file of cuts that can be performed by a CNC cutting machine. The North American license is held by Hewes and Company in Maine who sold me the kit, but to cut down on shipping costs have subcontracted the cutting on the west coast to Turn Point Designs in Port Townsend.

To me this is an amazing example of the new world we live in where a design can be transferred and machined anywhere. Although this process was reductive, ie: cutting marine plywood sheets. The concept is the same as the advent of 3D printers. The ability of a design to be shared and produced simultaneously in very disparate geographies. At the same time it will be a very traditional design wood boat, the juxtaposition make the prospect of completing the project all the more exciting.

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Seeing this pile of plywood was super exciting and at the same time I suddenly realized how daunting my goal was to turn this pile of two dimensional plywood into something three dimensional.

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