Build-A-Bear, mountain-style canoe

You can imagine how excited my niece was to learn that I would be building this particular style of canoe. As for the bear, the plans weren't specific as to species, so I am arbitrarily picking a laughing polar bear.

http://www.flickr.com/photos/4946066...n/photostream/http://www.flickr.com/photos/4946066...n/photostream/http://farm6.static.flickr.com/5290/...b6e81155_b.jpg

I live on the gulf coast of Texas, and when I ordered the plans I didn't see any gulf-coast style canoes listed among the plans, so hopefully the mountain style will still work in my local waters.



So here we go!

--Mike

NOTICE: If you are just starting to read this thread, I apparently screwed up a dozen or two of the photos by moving them to different Flickr folders. Sorry! But most of the images--especially the most recent--are intact.

Don't keep us in suspense. What plans did you order? Redbird? Prospector? Nice cap by the way.

It's the Prospector 16. Yes, the cap is key to my inspiration.

Oh my, no chance of Houston ever getting any snow now with all the saw dust soon to be flying about in a cloud of purple prose....or is that purple haze? Good to see the cap has begun to works its' magic too by ensuring the manual is right side up ! :D:D

It will get better and betterer Mike! Trust me!!


Cheers!


Peter, looking forward to another fine thread on canoe building!

If you have any questions along the way, my brother and I would surely answer them if they are within our realm of expertise. Several others here have built canoes and some have even built lots of canoes. Lots of answers to whatever questions you may have. Looking forward to seeing your Prospector come together.

The strongback is looking good.

So I know you folks will sympathize with me on this: To ring in the solstice today, it got up to 82 F here. The kicker was, I went out to clean the shop a bit and got SAWDUST all over my winter flip flops!

http://farm6.static.flickr.com/5170/...70f840aa80.jpg
But don't cry for me; I know that life could be worse.

So on to my canoe building follies. Carefully following the plans, I started with the strongback. I picked 1/2" OSB for the majority, simply because it was cheap at the home center. My recently completed deck was a better work area for me--my garage is still a mess.
http://farm6.static.flickr.com/5048/...8a9a80af20.jpg

Three sections to be joined together. That's Inspector Brody overseeing the process.
http://farm6.static.flickr.com/5082/...8b4e8b0a_z.jpg

... hopefully nice and straight ...
http://farm6.static.flickr.com/5290/...1f405781_z.jpg

and with the cap'n-approved 1/4 inch ...
http://farm6.static.flickr.com/5244/...3eef3668_z.jpg

and legs attached
http://farm6.static.flickr.com/5049/...f3c13d43f5.jpg
... it almost looks like a strongback.

More soon!

--M

Quote:

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Originally Posted by MoMan

You can imagine how excited my niece was to learn that I would be building this particular style of canoe. As for the bear, the plans weren't specific as to species, so I am arbitrarily picking a laughing polar bear ...

--Mike

---

I read someplace that polar bears laugh loudest when they are fed. I haven't met anyone with first hand knowledge, however.

In the older versions of Canoecraft, Ted used to use two by 10 T shaped strongbacks. I wonder when he switches to the Box style girder strongback in the newer books.

Quote:

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Originally Posted by MoMan

So I know you folks will sympathize with me on this: To ring in the solstice today, it got up to 82 F here. The kicker was, I went out to clean the shop a bit and got SAWDUST all over my winter flip flops!

http://farm6.static.flickr.com/5170/...70f840aa80.jpg

--M

---

Don't tell me you threw out the owners manual for your flip flops or worse, you ONLY have a pair of winter flip flops?! I know it may be too late, but maybe Santa could be faxed and a pair of summer flip flops added, near the bottom of your list,right after the porn collectors box set with the classics "Debbie Does A Canoe.", " Long Dong Silver Shoots The Rapids." and everyone's favorite," Bambi Eats A Beaver." I hope Santa's elves are checking the fax!


Good to see the 1/4" in there too. You can never be too fancy a butcher of wood!



Cheers!


Peter

With the strongback completed, for the most part, I moved it into the garage workshop and attached the top.

http://farm6.static.flickr.com/5089/...e2b01b30c7.jpg

Because of my inefficient (read: messy) workshop, I decided to make a modification to the strongback. This thing is going to take up a lot of what little space I have left, so I'm going to need to move it around, so I attached four swiveling, locking casters.

First, I needed to add a wider "foot" platform to which the casters could attach:
http://farm6.static.flickr.com/5245/...b50bb8a31d.jpg

(oops, looks like these are a little out of order: feet first, then attach top)

http://farm6.static.flickr.com/5003/...a028698f5c.jpg

My only concern is ...


























... is it TOO mobile??


http://farm6.static.flickr.com/5202/...0b19ce26_z.jpg

In all seriousness, having attached these casters, I am worried that I'm going to get a little frustrated by the movement they afford, even when locked, especially when I get to Peter's favorite activity, sanding.

I am already contemplating potential solutions, such as setting the legs on top of some kind of solid risers. Shouldn't be too difficult. Well, more soon.

Merry Whatever, everyone!

--M

With the strongback set up and mobilized, it was time to move on to the molds. Because this is my first boat-building experiment, I decided I needed a set of plans that any semi-educated chimp could follow. That meant setting aside my original plans from Randy Folsom's book, which required lofting from the offsets table. Yes, I'm a chicken. But I also know myself well enough to know that if it's not paint-by-numbers simple, I'd get frustrated and abandon the project. Therefore, I fell hard for the Bear Mountain Boat plans when I read, "Full-size plans."

And with full size plans that any six year old could trace, there's no way I could screw up, right?

http://farm6.static.flickr.com/5125/...836fbcff_b.jpg

This was my first station mold!!

I resisted the temptation to wad up the plans and throw the plywood across the garage. I decided one-half of my problem was trying to trace a smooth line onto the rough cheapo plywood surface. I went to the store and picked up a dozen sheets of poster board and set about transferring the lines from the plans with some carbon paper. Much better!
http://farm6.static.flickr.com/5041/...44544c80_z.jpg
Of course I jumped the gun and immediately started chopping up my plywood in the least efficient order, requiring me to buy more, but hey, I was making a little progress!

http://farm6.static.flickr.com/5287/...f7e24c13_b.jpg

Next up: attaching molds to strongback. (I know, the anticipation is KILLING you!)

--M

Quote:

---

Originally Posted by MoMan

My only concern is ...
... is it TOO mobile??

http://farm6.static.flickr.com/5202/...0b19ce26_z.jpg

--M

---

Judging by the photo,I'm surprised you have only one concern! :D As for keeping the rig in place while entering a state of exaltation, a simple case of 24s under each corner ought to do it......provided they haven't been drained already!

Keep at her Mike!!


Cheers!


Peter

Quote:

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Originally Posted by MoMan

http://farm6.static.flickr.com/5125/...836fbcff_b.jpg

This was my first station mold!!


http://farm6.static.flickr.com/5287/...f7e24c13_b.jpg

Next up: attaching molds to strongback. (I know, the anticipation is KILLING you!)

--M

---

Cheeses Mike, that first picture doesn't look too bad. The lines are straight and you've got yer 1/4" right thar! :D

Poster board/paper was a good work around!

The last picture however leads me to thinking you may,just may, find it very helpful to have yourself a mascot around just to keep you on the straight and narrow while helping you through the tough moments normal to any build. Mines' been a Godsend at times.Honest!

Has it at least warmed up a bit down your way? Winter flip-flops can be tough to work in after awhile.Summer ones is what you'll be needing to get this boat moving brightly along toward a launch.


Cheers!



Peter

Quote:

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Originally Posted by P.L.Lenihan

Has it at least warmed up a bit down your way?.

---

At 7:00 a.m. this morning, it is 65F--practically hat-n-gloves weather here in Houston! It did approach the freezing point earlier in the week, which always turns into the lead news story.

Having moved down here from my home state of Nebraska, I am always bemused when the locals freak out over colder weather. I saw one woman pour warm water on her windshield to clear the ice! If only they taught basic science anymore.

I meant to offer up a few more details on my methods of cutting the molds out--more for entertainment and explanatory purposes than as instruction for future builders.

With my poster board templates carefully traced and cut with scissors, I transferred those lines to the plywood, and with a jig saw, cut to about 1/16 outside the lines. I briefly considered using my bandsaw, but felt that the bigger molds would be unwieldy.

With each mold rough cut, I proceeded to the stationary belt/disc sander. Yes, unlike Tenner and others here, I am both a hack and a tool collector. Plus, I'm a shortcut-seeking, lazy wood butcher. But let me tell you, this is where the 48" belt sander excels. With an 80 grit belt, that thing is like a sponge for removing wood, right down to the pencil lines.

So with each completed mold, I rough cut its matching spouse and consummated their relationship with some drywall screws. With the two matching molds tightly embracing each other, a router with a pattern-making bit made quick work of identical molds. This way, I am assured of multiplying any mistakes I make!

--M

My $.02 on the stongback being mobile. Take your hole saw to some scraps of wood with the hole being just small enough to raise the caster wheel off the floor. Lift your strongback and slip these into place when you want to immobilize it.

BTW I read your thread title and though "Build-A-Bear", you know where the grandkids go to build a teddy bear, then mountain style canoe, OK he is building a mountain style canoe for the teddy bear his kid/grandkid just got.

Quote:

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Take your hole saw to some scraps of wood with the hole being just small enough to raise the caster wheel off the floor. Lift your strongback and slip these into place when you want to immobilize it.

---

That's even better than the old dog dish idea that my feable brain concocted. Thanks!

Quote:

---

BTW I read your thread title and thought "Build-A-Bear", you know where the grandkids go to build a teddy bear, then mountain style canoe, OK he is building a mountain style canoe for the teddy bear his kid/grandkid just got.

---

Ah yes, another hapless victim of my lame, tongue-in-cheek joke! But thanks for visiting.

Boat builders and bears have similar traits. Sometimes everything is bliss and they are happy. Then suddenly and without warning, they fly off the handle and start destroying things. But then things are ok and happy again. And just as quick, they get angry and destroy stuff.

These are called "Bi-polar Bears".

(duck and cover)

Quote:

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Originally Posted by tigerregis

Was that BearPaw beer in an earlier photo?

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Also known as Texas Thinkin' Juice! :D

Quote:

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Originally Posted by MoMan

Also known as Texas Thinkin' Juice! :D

---

Texas Thinkin' Juice?! Cheeses, I could use some of that...oh alright...I could use a whole lot of that! Anything to keep the gears oiled while the muscles toil!

So, any strips cut yet Mike? Type of wood? Bead and cove? Doing it on your own or having a kit shipped? Just wondering and harrasin' :D:D



Cheers!


Peter

Quote:

---

Originally Posted by Paul Montgomery

Boat builders and bears have similar traits. Sometimes everything is bliss and they are happy. Then suddenly and without warning, they fly off the handle and start destroying things. But then things are ok and happy again. And just as quick, they get angry and destroy stuff.

These are called "Bi-polar Bears".

(duck and cover)

---

Not to be confused with bi-boat builders.

Quote:

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Originally Posted by P.L.Lenihan

So, any strips cut yet Mike? Type of wood? Bead and cove? Doing it on your own or having a kit shipped?

---

Western red cedar strips were cut and bundled up according to each board they were cut from about a year ago. Then I put the whole project on hold while my wife & I resided the garage and built a deck. Then I came up with a million other excuses to procrastinate (it's too hot, it's too humid, I need more power tools, my hair's too long, etc. etc.). I also purchased a bead and cove router bit set.

But now the project is back on track, and I won't get my garage back until I complete the damned thing. So on with the fun!

After farting around and fiddling with the alignment, I got each station mold aligned and attached to the strongback. A line jig attached to each stem mold with fishing line stretched tight between offers a nice, straight line of sight.

http://farm6.static.flickr.com/5166/...33aac40d_b.jpg




And here, you can see the keel set in place, straight as an arrow:
http://farm6.static.flickr.com/5006/...ebd2aa2a_b.jpg

WHOA Whoa whoa!!!! Please! Set the flame thrower down, lower that barrel and slowly re-engage that trigger safety switch sir! That was only a joke!

As 99.9% of you already knew, this canoe does not call for a keel. That is simply a scrap strip to hold the molds in place until I could get the horizontal braces set up between each mold.

With all that accomplished over the course of a few evenings, I got out my trusty sighting tool: a pair of blue eyeballs, safely tucked behind my safety glasses, and started squinting, looking from different angles and in general, ogling the curves.

But station(s) #3 just weren't looking right. They were noticeably lower than the adjacent stations. CRAP! I've f*'d up again! I got out my sanding block, dreading the task of sanding down multiple stations to the level of stations 3. Then it occurred to me: what if I lift up station 3? It had to be parallel, so I stuck a couple of steel rulers under it, raising it up (wait for it ... wait for it ... )

http://farm6.static.flickr.com/5082/...f5b85436_b.jpg

1/4" Brilliant!

More fun is just around the corner!! Until then, Happy New Year!!

--M

Quote:

---

Originally Posted by P.L.Lenihan

The last picture however leads me to thinking you may,just may, find it very helpful to have yourself a mascot around just to keep you on the straight and narrow while helping you through the tough moments normal to any build. Mines' been a Godsend at times.Honest!

---

You know, it's funny you mention that. The other day I was working with the garage door open when I hear,




Hey Mr. Mike!





Oh crap. It’s Andy. I’ve been working with the garage door open and that pesky kid from down the block can see me from the driveway.





http://farm6.static.flickr.com/5203/...4a16071c_b.jpg

I don’t know much about … him? … her? All I know is that his/her parents recently moved into the neighborhood and its? father is a pubic relations executive for a big Milan-based energy conglomerate—Gen-Italia. It goes without saying, it is privately held.

I sense the makings of another great build thread..............

Oh my, I hope Simon doesn't see this! With his extensive experience managing large groups of workers,he may try to coral young Andy into joining his"team". Be careul Mike and if you do take on Andy, a bit of sandpaper waved in front of his nose,once in awhile, should be all it takes to keep him on the straight and narrow road of progress! Done right, you and Andy should have yourselves a fine canoe done by this coming summer. Is Andy old enough to drink beer? You might want to nip this in the bud before he gets a liking to your private reserves!


Cheers!



Peter

To continue with my little tale, my neighbor Androgyny (Andy for short) stopped in to inquire about my activities in the garage.

"I'm just getting started on a canoe--it's a cedar stripper called a prospector," I explained.

http://farm6.static.flickr.com/5245/...322f254844.jpg

Well Andy, like I said, I'm really just getting started on the initial construction, so the life jacket is a little premature. I'm afraid you'll just have to be patient like everyone else around here.

"Wow! A cedar stripper! That's so cool! My mom was a stripper when she met my dad."

Well, that's more than I needed to know. The stripper part of the canoe I'm referring to is the long, narrow strips of cedar which form the hull. Now if you're going to be in the shop you're going to need to wear these safety glasses.
http://farm6.static.flickr.com/5003/...9436798d_z.jpg

"Aahh! Is this how these are supposed to fit?? Mr. Mike, do I still have to wear safety glasses if I don't have any eyes?"

Well, I suppose that's a valid point. I guess not.

Now, if you can sit quietly while I get back to the real topic at hand, I will let you stay and observe.

So as I mentioned previously, I bought my western red cedar beams about a year ago. At that time, I was planning to use Randy Folsom's book to build a 15 1/2' canoe. Mr. Folsom assures the reader that less-than-full-length strips are perfectly acceptable and to compensate, the builder would need to make some simple scarf joints. I believe all my strips are about 12', which means virtually ALL my strips will be scarfed. So, will this be a problem for me? Should I just light a match to the hundreds of dollars I've already invested and start over? (please say no). Or am I just going to end up with a butt-ugly canoe? Thanks for stoppin in!

--M

Scarfed joints will work. You may even be able to play them to your advantage to get some interesting patterns and colours in the planking. Think design features within the planking. Lots of potential. I am also jealous of the fact that you paid so little for your planking material.

I've been away for a week or two, so I'm just checking in to this thread. Couple thoughts.

First, I think this canoe will be a fine project and will turn out just fine.

Second, I think you might want to wear that helmet a little more often.

Well, as of this posting, I've hit a very exciting milestone. Up until now, I have only been building the strongback and the forms. I have now officially cut the first pieces of wood that will actually be a part of the canoe. I know that like me, you can hardly contain yourself!

The parts I cut are the stems. Let's start with the inside stems first. The plans assure me that softwood is perfectly acceptable, and actually preferred over hardwood because it will accept staples better than hardwood. I looked over the scraps in my lumber rack and found some fairly straight grained pine. I took it to the bandsaw and resawed it into some 1" wide by 3/8" thick strips about 40" long. Then I sent the strips through the planer to remove the saw marks, evened out the minor dips and waves from resawing and reduced them to 1/4". Knowing that bending these strips over a form meant a high probability of potential failure, I milled a handful of extras. It is so much easier to make an extra batch while the machines are set up versus going back later and trying to recreate those settings accurately.

So, with the stem strips all machined to size, it was time to prepare for bending, and that meant steam. I needed a heat source, a proper vessel in which to heat water to steam, and a container the right size to hold the strips, but not so large that it takes hours to generate enough steam. At first, I searched for the plans-recommended 2" PVC pipe, but all I had was too big or too small. Then I remembered some thick metal pipe that an electrical contractor left for me years ago when I upgraded my shop's electric sub panel. Then I borrowed my wife's tea-pot (don't tell her), and dug out my trusty and somewhat rusty old backpacking stove. A couple of pieces of plastic tubing made a nice, tight transition from teapot to metal pipe, along with a stuffed rag. At the other end, the strips are inserted and the end of the pipe blocked with another rag. Here's some pix of the set up:
http://farm6.static.flickr.com/5081/...c481a4b0_b.jpg

http://farm6.static.flickr.com/5002/...2c5ff899_b.jpg

For the actual stem steaming, I moved the operation indoors. Some gloves and some tongs for handling and I was ready to fire up the stove.
http://farm6.static.flickr.com/5129/...5fa7ecc6_b.jpg

... continued ...

On with steaming: With the mid-1980s coleman stove reliably chugging along, the water slowly warmed to the requisite temp. Eventually, the far end of the pipe started emitting some light wisps of steam. I slipped a pine test strip into the end, stuffed a rag in, started the timer and had a heapin' helpin' of Texas Thinkin' Juice while the stove did its magic. After about 10 minutes, I noticed the steam at the end had dropped down to nothing. Phuque! I looked over the operation and saw that the reliable stove had betrayed me: there was no flame, which is a prerequisite for steam. I let the stove cool a bit more before handling it and realized my rookie mistake: the fuel had run out. Idiot. So I opened the tank and this time, filled it to the top. Then, it was back to the beginning. Start the stove, wait for the steam, set the timer, drink the beer, anticipate fun.

Between sips, I used the 15 minutes to get my clamps ready and set up within reach of the stem mold. A little after the 15 minute mark, I pulled the rag out and extracted the hot, wet, limp piece of wood. I was delighted to see it bend easily around the form without cracking, and clamped it in place. Success! Next, it was time for the actual pieces. With the stove fuel tank refilled to the brim, I cranked it up on high and waited for the steam. OK, it's the same damned process, so I won't bore you with the repetitive details yet again. Anyway, 15 minutes/12 ounces later, the three strips were ready for bendin'. Extract, clamp, bend, clamp, crack, CRAP!!!. Yes, all three of this first group of strips showed signs of failure at different areas--not surprisingly, at the various knot holes.
http://farm6.static.flickr.com/5006/...2180b2ed_b.jpg

This is where the extra strips I milled were especially appreciated!! So, repeat process. But this time it actually worked:
http://farm6.static.flickr.com/5249/...0812a633_b.jpg

Yeah!

--M

I like innovation and invention. . What more would a man need than a sawhorse with adjustable legs and a wee table built beneath it. And retractable wheels, (I dunno why you don't have wheels like that on your strongback),on the outer corners of another. Smart.
More than I can say for that dumb blind kid from down the road, Andy. Wearin' a lifejacket when he is made of wood.

Quote:

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Originally Posted by floatingkiwi

I like innovation and invention. . What more would a man need than a sawhorse with adjustable legs and a wee table built beneath it. And retractable wheels, (I dunno why you don't have wheels like that on your strongback),on the outer corners of another. Smart.
More than I can say for that dumb blind kid from down the road, Andy. Wearin' a lifejacket when he is made of wood.

---

Yup! Mike is one smart rascle Kerry, with a shop full of nifty tools and stuff but ya know something, Andy ain't too shoddy either! He knows enough to be prepared for waterloggeddom should Mike toss him out of the canoe miles off some shoreline, just before they get to the last bottle of that Texas Thinkin' Juice ......


Cheers!


Peter

Waterloggeddom? I've learned a new boatbuilding word. I love this place. JayInOz

Quote:

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Originally Posted by floatingkiwi

Wearin' a lifejacket when he is made of wood.

---

About as logical as me wearin' a helmet without a brain!

Quote:

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Originally Posted by floatingkiwi

... And retractable wheels, (I dunno why you don't have wheels like that on your strongback),on the outer corners of another. Smart.

---

Ahh--it just occurred to me which wheels you were referring to. Those are on the base of my homemade planer (DeWalt lunchbox style) stand. The base is from some nice, thick maple and is rock solid/stable. It's also fairly heavy, necessitating the retractable wheels, which are intended for contractor-style saws. Although they work great, between them and the splayed out legs of the base, it's a big waste of space. I might as well outfit the planer with a hula hoop. Making a more space-efficient model is on my long- and ever-growing list of projects.

MoMan:

Just to keep you motivated and inspired, I think you will be very happy with the Prospector. I have a 17 foot Chestnut Canoe Company Prospector wood and canvas canoe. It is my favorite tripping canoe.

These are all Prospectors: From front to back - A 16 foot wood and canvas reproduction Prospector home built by a friend of mine, my red 17 foot Chestnut Canoe Co. Prospector, and a green Chestnut Canoe Co. 18 foot Prospector. My friends and I trip in these canoes all the time and have nothing but good things to say.

http://inlinethumb05.webshots.com/10...600x600Q85.jpg

Fitz

Hey Fitz--Thanks for sharing! Yes, I can use all the inspiration and motivation I can get.

You-know-who did an unannounced drop in.
http://farm6.static.flickr.com/5123/...d3ee302dd9.jpg

Well Andy, that is one of the many mistakes to come in this project. When I traced out the template, I must have placed it a little low on the plywood. Hopefully this won't adversely affect the outcome. Now, it's time to epoxy the stems. Can you mix me up a batch--one pump of resin, one pump of hardener.

Then, after thoroughly mixing and adding some thickener, I can spread it on and you can help me tighten the clamps.

http://farm6.static.flickr.com/5249/...2bae039f_b.jpg

There! Nicely done. If I had enough clamps, I could do the other stem tonight also, but we'll have to wait until tomorrow.

So I got the inner and outer stems all laminated up with epoxy, and I'm please with the results. Knowing how sloppy and inexperienced I am, I made everything considerably wider than the finished size. When they came out of the clamps a day later, I scraped off the bigger epoxy blobs with a chisel and card scraper. I experimented with running them over the jointer, but the sharp curve made it impractical to do it safely. I did run the super wide inner stems through the bandsaw for a rough width. Then I turned to one of my favorite machines, the DeWalt surface planer. Right off, I encountered an issue. I set the depth stop to 3/4", more of a disaster prevention measure than an accurate setting. After a couple of initial runs, the crank was turning so hard, it felt like it was up against the depth stop, which was impossible. I sent Andy in for a closer look:
http://farm6.static.flickr.com/5128/...f97acce2_b.jpg
A little T-9 Boeshield sprayed on the four threaded posts and it loosened up like a winning slot machine!

So the stems all came out of the planer looking fine. BTW, I'm using cherry for the outer stems, in case anyone's wondering.

... continued ...