First Post - First Build - a Lightning

[Mike Seibert]

Hi - brand new member - I'm recently retired and have decided my winter project will be building a Lightning in my garage. I'm a novice builder but have lots of patience and time to learn.

My plan is to build a Lightning according to the plans developed in conjunction with the Woodenboat magazine build back in 2000. I have purchased the plans and have my Lightning # and also have the three magazine articles from Woodenboat. I have also read but frankly don't completely understand some earlier articles in Woodenboat about lofting. I also have the Lightning Association publication on how to build a Lightning.

Anyway, I'm about to retire my golf clubs for the season, pick up my hammer instead, and tear into this project (slowly, I promise).

Is there anyone out there who has done the same project? What did you learn that you wish you had known before you started? What else should I know before I start? If you did the build, how much did it weigh? Did it pass the certification process for Lightning racing? Would you do it again? How did the boat perform? Where did you get everything for rigging, etc?

The Woodenboat builders used three 1/8 layers of cedar, soaked in epoxy, for the bottom planking. They used marine plywood for the topsides and decking. The bottom frames were spruce (maybe sitka spruce) and the topside frames were marine plywood.

I live in Vermont - any ideas on where I could find reasonably priced sitka spruce for the bottom frames? The Lightning booklet says that you can also use red spruce instead. Other ideas for strong but light bottom frames?

I need to get a number of tools for this project. I have a decent table saw but that is about it. I will need to get an assortment of planes and chisels. But my question is - the articles talk about using a band saw a good bit. Is the band saw a necessary purchase to get this build done right?

Lastly, I would love to take a class in boat building but can't find one for this Fall or Winter. It looks like the only week-long classes run from about May until September, and I have missed them for this year. Is anyone aware of basic boat building classes that are happening in the Northeast this Fall and Winter?

Thanks in advance for your advice.

[SBrookman]

Welcome to the forum and to boatbuilding. This is the place to be to learn how. I learned to sail on Lightnings many moons ago but never built one. My wife and I built models purchased from our host a few years ago:
http://stevebrookman.com/images/ModelsLightning2.jpg

I highly recommend building a model first to get a feel for how the real thing goes together. Others will come along and help you with info on building it full scale.

Have fun it's a great pasttime even if it takes up lots of time.

[Pokey]

I'm a carpenter not a experanced boat builder but I find a good jigsaw works fine. Unless your going to spend $2,000 ($@,000) on a comerical band saw I would not bother every small band saw I've ever worked with made me go back to my jigsaw.

[andrewe]

Well Pokey, I was looking at a major house restoration (and a small boat build) so I justified a basic planer/thicknesser and a small bandsaw. The b/s cost under $200. And for what I want, it does a very good job. I have a Bosch jig saw, but the bandsaw does great work. Horses for corses.
A

[ILikeRust]

A bandsaw is extremely useful and if you spend some time scouring the used machinery market, you can get away with spending far, far less than $2,000 for a good one.

I have a late 1930's Walker-Turner 16" bandsaw - nearly 500 lbs of good ol' `murican cast arn - that I got at an estate auction about 12 years ago for $100. It was not plug-n-play when I bought it, but after a full restoration it's a right sweet machine. I've got a total of less than $500 in it at this point, and that includes the mobile base.

A couple years ago I acquired for a friend of mine a 1960's Rockwell/Delta 14" bandsaw via Craig's list for $400. It was (and still is) completely plug-n-play. Runs very smooth and tracks very straight.

Take a look at Craig's list, eBay, find a local used machinery dealer - they're out there.

[Eric D]

Grizzly 0555 14" bandsaw with riser gives you a 12" cutting height. Table saws are great, bandsaws just make certain cuts soo much easier. IF you have the space and money and the "need" for one, I say sure, buy one. Once you learn to use it, you will love it. I will mail you my jig saw, I NEVER use that thing anymore (ok, that one cut a year...) Craigslist can be your friend.

Bob Smalser is a name of a wood guy on here who I would trust asking for info on changing wood. Search his name and send him a PM. There are others as well who have a repository of great info.

As for lofting. Several different sources for info. Wooden Boat has several books available to buy to discuss, I am sure some are in your local library as well. It is worth the effort needed to get that right or else any boat comes out wanky.

I have never built a lightening, but several smaller boats. I will say this. Getting your feet wet building ANY thing smaller with SIMILAR construction methods will be a savior so you can get a sense of what goes where and how tricking this or that can be. Building a scale version/model is often suggested for practice, but some find the small scale too frustrating.

Either way, good luck, post lots of questions and pictures as the more you post pictures the more responses you get. It is kinda the grease for the info deal LOL.

Have fun and congrats on retirement.

[wizbang 13]

I miss my old Lightning, 9693, I have wonderful dreams about it after 20 years. Great boat.
meanwhile, I have built many small and half a dozen "large "vessels. never had a bandsaw or a stationary planer. The most usefull too I ever had , especially as a cold molded bottom/epoxy is concerned is thishttp://farm5.static.flickr.com/4023/4661992490_7492f258da_z_d.jpg

[TerryLL]

Mike,
Welcome to the Forum. The Lightening looks like a fun first project, not too difficult but certainly challenging. And when she's done you'll have a real performance sailboat.

I'd highly recommend you buy yourself a bandsaw, and you don't need to spend two grand. You can get a first-class saw for under $500, as others have already mentioned. If I could own just one stationary tool for boatbuilding, it would be a bandsaw. The $400.00 Delta I bought in 1987 is still going strong.

We will need to see photos of your project as it advances.

[RodB]

I encourage you to just bear down and educate yourself as you go along. You will have a great time and learn a lot. Tons of lightnings around and with such a strong class there will be plenty of sources for help. I'm thinking the Woodenboat article was about a cold molded boat which will be a bit easier than a splined/planked traditional build from the past. There are some good books on cold molding and general boat building, and it sounds like you certainly have the basics to get started.

I'd certainly recommend at minimum you acquire a quality jig saw, with the Bosch 1591 or the Makita 4385 (barrel grips) as the top two, oops, don't forget the $320 Festool, which is a damn fine saw but expensive. I chose the Makita barrel grip jigsaw because it has a built in LED light, and runs smoother than the Bosch. The Makita also funnels a jet of air as you cut keeping the sawdust away from the blade. All three of these tools are solid machines and easy to use. Any one of these will show you how a jigsaw is supposed to feel.

I would also recommend a Jet or Delta 14" bandsaw, I don't know how I ever got along without one. I see them here in Dallas on Craigslist all the time for $300-$450 with mobile bases included. It will last you a lifetime and when you need one, its great to have it. You will certainly need a quality low angle block plane. There are plenty of choices here, I bought the Lee Valley "original" Low Angle Block Plane several years ago and have never regretted it. Many here can offer suggestions here. You will also use a stationary beltsander/disc sander... , the smaller Ryobi at Home Depot (just over $120) will last a long time and does a decent job.

Some good refenence books worth having: "The Gougeon Brothers on Boat Construction", "The Laminated Wood Boatbuilder" by Hub Miller, "Cold-Molded and Strip-panked Wood Boatbuilding" by ian Nicolson, "Building Small Boats" by Greg Rossel.

Good luck,

RodB

[donald branscom]

Welcome to the forum and to boatbuilding. This is the place to be to learn how. I learned to sail on Lightnings many moons ago but never built one. My wife and I built models purchased from our host a few years ago:
http://stevebrookman.com/images/ModelsLightning2.jpg

I highly recommend building a model first to get a feel for how the real thing goes together. Others will come along and help you with info on building it full scale.

Have fun it's a great pasttime even if it takes up lots of time.

Very beautiful models. You will get to enjoy them for the rest of your life.
I suggest putting them in a space that protects them from dust.

[rbj37]

If you have not already done so, join Yahoo Groups--Wooden Lightning. Very friendly and lots of information.

[Mike Seibert]

Thanks. I am a member of the Wooden Lightning group, and that's where I first saw a mention of the band saw jig.

[Tom Robb]

I suppose it's possible (although unlikely) that you'll have a finished Lightning by Spring's golf season.
The model suggestion may be a good one for you. Build from scratch (no kits) 1" to the foot, chapter and verse by the plans. You'll learn something about she goes together.
Buy tools as you discover the need. The jig saw and block plane are a reasonable start. You don't need boutique tools even if they're nice to look at, but avoid hardware store junk. Used older hand tools may be the best bargains in town. You certasinly do not need a 30's era Walker Turner ship's saw to build a Lightning even if it'd be some serious bling to show your buddies.
There are boats built of unobtanium, but most are built of whatever is available. WB magazine has ads for several lumber dealers that will have whatever you could possibly need. Some in the NE.
Take a class next summer; whats the rush. You'll have fun, learn something, and meet like minded new friends.