Whilly Boat Cost

[casem]

A couple people have emailed me about how much it cost to build my Whilly Boat so I figured I'd post this to scare off prospective builders. Keep in mind that I kept track of every cent, from the plywood to the plans and paint down to the screws used to hold the planks together while the glue dried. Prices are US$.

I tried to break it down as follows (the break down is less accurate):

Tools - anything that I could conceivably use for another purpose, like drills and planes etc. I started with just a couple of screw drivers and a 5 gallon bucket full of rags, so you might be able to save alot here. Also I bought more than I needed.

Hull - Everything needed to build the boat: plans, jig, wood, epoxy, paint, varnish, + disposable stuff like foam brushes, rubber gloves, solvents, temporary fasteners, tape, tack rags, plastic cups, etc. Hull is planked with okume and all solid wood is B mahagony, except spars and floorboards that are Douglass fir. The hull is decked and coated with epoxy with fiberglass on the garboards, so that might provide some room to save.

Mistakes - stuff I screwed up and had to redo.

Fitting Out - Bronze hardware and fasteners, wire rigging, line, cleats, compass, blocks, leather, oars, dolphinite, anchor and line, etc, but not stuff like VHF radio, flares, PFDs, EPIRB, Loran (just kidding about the last two). This figure really suprised me. Bronze hardware from Classic Marine.

Sails - home made from Sailrite kit for the sloop rig. Includes grommet tool rental.

Trailer - includes an expensive hitch for my car and also modifications I had to do to get the boat to fit. Could definately save here, especially buying used.

Here goes:
tools 1282
hull 2343
mistakes 61
fitting out 753
sails 247
trailer 789

I can't bring myself to total it up but I'm sure it was all well worth it. Estimate for time to build is maybe 1200 hours.

[NormMessinger]

I'd say you done good. How much of that was shipping? That's what really really adds up out here twixseas. Two snap shackles $7, shipping $5 and never do in one order what I can drag out to three or four.

I only charge tools that are unique to a project to that project. But just think, in your case, you're 1200 ahead on your next boat.

Life is good.

--Norm

[gert]

Tools don't count; ya dont need an excuse to buy tools. The sails and trailer came in cheap. I had to buy a whole sheet of akume due to just one of my mistakes so I think you did good there.
Well done. So now you have to get her out on the water lots to bring the fun cost per hour way down.

[casem]

I guess I'm lucky in Maryland because I didn't have to order much, just the plans, the sail kit, and the stuff from classic marine. Everything else was local.

I don't really count the tools either. Might try to make some furniture before my next boat so they really will end up paying for themselves.

[Meerkat]

Uhhh... OUCH!

Leaving aside everything except boat & rig, I am having trouble seeing how it could go much over $2000. So far I've gestimated about $700 for ply and timber (based on local timber supplier quotes. Bronze jewellry looks to be about $200-$250 from Classic Marine. The rest is googe and consumables (brushes, rags, rollers etc.) no?

I too am probably going to have to take the bite for a trailer. $425, including freight, gets me an EasyLoader "socket and screwdriver" kit delivered by UPS and then there's the hitch. I expect the trailer will need some tweaking. (Speaking of trailers, will I need a keel support in addition to bunks, or are the bunks alone sufficient on such a light (est: 200# ready to cruise) boat? Also, this trailer will have the boat's last 6" off the end - is this OK?)

I am lucky in that, while I own no tools, I have access to a complete woodshop and tools for my first boat. I expect to pay a shop charge for tool wear though (blades etc.).

casem, did you try getting a quote for loft-made sails, like from the Aussies at Duckflat? I did notice that the Sail-Rite gunter main and jib kits for the WB are about $225 plus shipping and the grommet tool rental (probably be able to find one locally here).

I really don't wish to give offense here... Iain suggests 180 hours for a WB - what took so long? I would have thought 360 hours at most... ?

[casem]

I don't know Meerkat. But I also expected 2000 when I first started. I'll list some of my big purchases:

plans 93
plywood 460 (5 sheets of 6 mm and 7 mm)
solid wood (mostly mahogony) 420
epoxy, cabosil 340 (I coated the boat with it)
doug fir for spars and floorboards 218
main sheets, halliards, lacing, wire rigging,thimbles 200
oars 135

That leaves out the obvious like paint, thinner, and varnish, But it also leaves out all the disposable gloves, plastic bowls and forks, sandpaper, foam brushes, foam rollers, and masking tape. All that junk adds up. Back when I was building, it seemed at least once a week I'd be out buying at least one of these things. Go to Costco and buy in bulk while you still can.

As for the time, I could be way off here. But it can't be less than 600 hrs. I probably spent 180 hrs just finishing. I wonder if Oughtred's figure includes that. If you don't varnish you'll save alot of time. Also, I think I could build a second one in much less time.

[casem]

As for the trailer, I don't have a keel support, just two bunks laminated to fit the curvature of the boat. It seems fine to me, but that's not to say I shouldn't have the keel support. My boat hangs at least a foot off the back.

I got one quote for sails that was about $900. I didn't try anywhere else because I wanted to make them. That was about a 40 hr job, counting learning how to sew.

Are you planning on keeping track of your reciepts? All you need is a big envelope. Then you can add it up in the end. Don't count your beer though; that will really put you over budget fast.

[gert]

We built our own trailer for the shearwater(sim to whilly). It has pivoting bunks (with two layers of carpet)at each boat frame and a plate under the center board;not as a support but to catch it should its rope give in transport.The center board is off center and would hit the road if it were accidently released.

[Meerkat]

Hey casem;
Thanks for your graceful response to my prickly question smile.gif

I hope that Barrett's knowledge and tools will make the work go faster. I would really like to go sailing next summer!!!!!!!!!!!! It's been FAR FAR too long since I was last on the water (not counting floating docks ;) ). Of course, cash flow is going to have a bearing on that <sigh>

Yes, I'm going to keep receipts, if only to ensure I don't face a sales tax assesment if I ever have to register the boat. Fortunately, unpowered boats under 16' don't have to be registered in WA state, but I don't underestimate the greed of our state politicians.

Have you ever taken a look at Bill Sargent's micro sailboat site? He modified a "Storm Petrel" (www.swallowboats.com) design for serious cruising. This is a double-ender with virtually the same specs as the WB. One interesting change he made is to put a shallow (8"!) keel on his boat and omit the c/b. An interesting notion. I kind of like his decks too.

Bill Sargent's site. (http://www.smallsailboats.co.uk/)

I think it would change the WB's character a bit, but it would sure facilitate cruising and sleeping aboard. Might have to drop a line to Mr. Oughtred smile.gif There are boats quite similar to WB from Scotland that have a shallow draught keel in lieu of a c/b... (Really just thinking out loud here).

Prices you mentioned for ply and timber are roughly double prices i've been quoted. 6mm BS1088 Meranti is $40/sheet here, so that's $240 for 5 sheets (assuming 1 sheet for the fore/aft decks). Likewise, Meranti timber here is $3.54/bd. ft. and Purpleheart is the same. On the other hand, due to a punitive tariff on wood from Canada, Fir is $7+/bd. ft.! Teak is only (!heh!) $12/bd.ft. (One considers teak for the faux laid deck on the fore/aft decks, but not too seriously.)

I have emailed a local sailmaker for a quote, but have heard nothing back yet. I'm guessing that, this being the slow season for sailmakers, they've decamped for places warmer for some sailing or something. If I don't hear from them soon, I'll try another email and if worst comes to worst, I'll use my secret weapon: I know they're right next to Brian Toss the rigger guy's place in Port Townsend and I'll ask them smile.gif

Gert, interesting news about the homemade trailer - you have access to a welder etc.? I don't know the ins and outs of making a trailer street legal...

It's great to be able to talk with you builder folk about all this before I have to actually go and spend the few pennies I can afford for this! Thanks to all!