Gartside Yawl Construction

[Dave Lesser]

After 4 years of conceptual work and design, Eric Jespersen has finally begun construction on Paul Gartside's design #160. The plans can be seen in the New Canoe Yawl thread in the Designs / Plans section of the Forum.

Now that something tangible exists, I thought that a thread in Building / Repair would be in order. I'll keep this Flickr site updated with photos as things progress.

This project would not have been possible without the wisdom and knowledge that has been shared by so many members of the WBF. Thanks to all.

Here's where things currently stand:

[rbgarr]

Different construction than described in a 2008 post?

Hull will be cold molded. Inner layer of 3/4" western red cedar laid fore-and-aft, then 2 diagonal layers of 1/8" WRC, and an outer layer of fore-and-aft 5/16" douglas fir with glass sheathing.

[bott]

I am very much looking forward to future posts in this thread.

What a great design and execution!

[Dave Lesser]

Different construction than described in a 2008 post?

Hull will be cold molded. Inner layer of 3/4" western red cedar laid fore-and-aft, then 2 diagonal layers of 1/8" WRC, and an outer layer of fore-and-aft 5/16" douglas fir with glass sheathing.

Eric has found that it is inefficient to spile and fair the 3/4" inner layer. He can vacuum bag multiple layers of veneer to result in an equivalent thickness more quickly. It is less work to fair the temporary ribbands than it would be to fair the solid first layer of 3/4" stock. The new scantlings call for 5 layers of 3/16" WRC laid diagonally, with the outer layer of 5/16" doug fir running fore and aft. Paul concurred with the change. The first layer of veneer is edge-glued and stapled to the ribbands. The staples are then removed and the remaining layers are all vacuum-bagged. This does result in diagonal planking on the interior, but it will all be behind cabinetry, covered with ceiling, or painted, so it is not an issue cosmetically.

[rbgarr]

Sounds eminently sensible. Good luck and she looks like she'll be a stunner.

[Dave Lesser]

Moving right along:




Vacuum bagging the stern:




More progress photos here


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[rbgarr]

elegantly done

[Dave Lesser]

Third layer bagged:

[Dave Lesser]

The six diagonal layers of 3/16" western red cedar have all been applied and vacuum bagged. They're now fitting the outer, fore-and-aft layer of 5/16" douglas fir planking. These are held in place with temporary fasteners until they're all spiled, then final gluing.



More progress photos here. Click on a photo to enlarge it.


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[44xt]

How are the shape of those outside "Planks" determined?

Are "Plamking Belts" laid out at regular intervals and then intermediate shape planks fitted? Or is the circumference found at each station and then divided up evenly?

Beautiful work!

[Dave Lesser]

How are the shape of those outside "Planks" determined?

The outer fir planks are laid fore-and-aft so that if there is any "print-through" the fiberglass sheathing, the lines won't be on the diagonal. The planks are tapered at stem and stern, but I'm not sure whether there will be a "football" (as in strip planking) below the waterline. We should know in another week or so. WRC was chosen for the inner layers for rot resistance and lighter weight, while the final layer is Douglas fir for better hardness.

Here' s where things currently stand:



Additional photos here.



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[Lew Barrett]

Dave, are you visiting the yard at any time this summer? Say during the the week between the Victoria and PT shows?

Great choices, she will be amazing.

[bloggs68]

Great thread Dave,

Are the outer planks scarphed or just butt joined and is there going to be any external cloth sheathing ( glass/dynel etc?) We are doing a cold molded overlay over carvel at the moment and it is always interesting to see what the other guys are doing. It is such a strong way to build and really not a lot more effort than other methods.

regards,

AD

[chuckt]

Love the design. I will be following with great interest

[Dave Lesser]

Lew,
I'm hoping to make it to Sidney sometime in August or September, but dates are still up in the air.

Andrew,
The outer planks are butt joined, not scarphed. I was concerned about that, but deferred to Eric's expertise and experience. He has assured me that since it is a single, glued, monocoque structure, there shouldn't be significant longitudinal movement. The hull will be covered with epoxy and glass sheathing.

[Dave Lesser]

Last layer of planking continues. From here on up the planks will be narrower like strip planking so that there is no need for backing out at the turn of the bilge. Additional photos here.

[Dave Lesser]

Meanwhilst, even before the last layer of planking is complete, the ribbands have been torn out, and 2 out of every 3 station molds have been removed. Here is what the inside looks like now. 'scuse the dust.

[Dave Lesser]

Whiskey Plank - well maybe not in the traditional sense, but the bottle was empty.

[Dave Lesser]

More progress photos can be seen here.

The hull is faired, nearly ready for sheathing.





Adding deadwood and shaping the prop aperture.




Installing chainplate blocking. Marking positions for floors and bulkheads using a laser level.

[Allison]

Bump.
There are a lot more new photos at the flickr site

[Eric Hvalsoe]

Fascinating. The son carries on the work of the father.

[Dave Lesser]

Work continues on the interior with the hull inverted. Bulkheads, floors, engine beds are now installed.



The plug for the ballast keel is test fit before it goes to the foundry



Glass sheathing is next. Should be ready to turn over in a couple of weeks.

Latest photos at this Flickr site

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[Allison]

One of the threads that I always watch for. Thanks Dave.

[Dave Lesser]

Applying fiberglass sheathing. 17-ounce biaxial cloth and West Proset epoxy for the keel/deadwood. The rest of the hull will be covered with 9-ounce cloth. Other photos on the Flickr site.

[Dave Lesser]

Quite a momentous day at the Jespersen boat shop today.

Out she comes:



Carefully, carefully . . .



Right side up

[Dave Lesser]

.
Using the ballast mold plug for blocking:


First look at the sheer



Safely back in the shop


Other photos on the Flickr site.

What a relief!!

[John Turpin]

Stunning.

[Ed Armstrong]

Hull is very shapely. Nice to see her right-side up.

Ed

[chuckt]

Agree with Ed. And she looks very salty. I need to go look at your design thread.

Just came back from the design thread--oh my. She's perfect. Exactly what I would like one day. I hope you forgive an impertinent question but would you mind sharing the building cost? It's not just idle curiosity. I'd like to have an idea of it for my musings on how I can obtain a crusier like this. I can certainly understand if you wish to keep the numbers private.

[chuckt]

Anything new Dave?

[Dave Lesser]

Form for the cabin top with laminated beams. Inner layer will be 1/2" V-groove cedar planking laid fore and aft, covered by 2 layers of 1/2" plywood, epoxied and vacuum bagged.




Foredeck framing continues. Beams notched for king plank.



Fitting cockpit carlins:



Aft deck framing:



More images at this Flickr site. Click on an image to enlarge it.
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[Peacefuljourney]

That's a whole amount of glue. Did it was fun to do? As I am cursing most of the time working with glue, specially epoxy (Resorcinol clean with water until it's cure, easy to clean the tools).

Nice work can'T say the opposite, but I just remember why I prefer carvel

[blindbrook]

Dave, it has been extremely interesting to follow your thread(s) and watch the evolution of this terrific project. While it is of course a compliment to you, it is interesting to view this in the context of the forum and what you have gleaned from other forumites. As they have done for you, you are doing for others. Thank you.

[Dave Lesser]

Engine and fuel tank installation:



Overview of main cabin:



Additional photos here
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[Dave Lesser]

Things are moving along. Here is the main cabin with mock-ups being installed. On the port side, the settee will pull out to make a berth. On the starboard side, a pilot berth will pull out above the settee. Reading chairs are being installed forward of the settee on each side.



Here is the aft deck and cockpit cutout.



More photos on Flickr.

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[darroch]

This is a great picture...she's surfing!

[Ed Armstrong]

Santa is looking to go for a sail...

...Things are moving along. Here is the main cabin with mock-ups being installed. On the port side, the settee will pull out to make a berth. On the starboard side, a pilot berth will pull out above the settee. Reading chairs are being installed forward of the settee on each side.


Here is the aft deck and cockpit cutout.



...
.

[Dave Lesser]

The deck has all been laid down. Two layers of 3/8" plywood.



Cockpit well and coaming.



Galley roughed in.



Port bow - right side up:



More new photos on Flickr.

[P.L.Lenihan]

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Damn! That is one sweet and hypnotic sheer and so soon!! Going to be a mesmerizer once the rub rail is on her!!


Cheers!


Peter

[keyhavenpotterer]

Beautiful. I guess she's pretty light still without ballast, deck, rig or interior, so excuse me for getting anal, but shouldn't that crane's straps also have athwartship steel bars accross the straps to prevent compression loading the hull, especially as she doesn't have a deck yet? They're not diverging but converging above her.

She's a sea of beautiful curves. So tell me to get lost, it's not my boat and never could be, but impartially the only straight lines I can see are those two straight pieces forming the aft bottom of the cockpit well. Being angled like that, they may stand out amoungst all her beautiful cures, right where your sat at the helm. They might bug you. Your paying professionals for this work of art, I'd tell them to take that out, steam some timber and make it a sweeping curve. Maybe that's not possible, always stick to the plan and all that, but straight lining things is a bit of an amateur mark, and it stands out to me. Tell me to get lost, I'm only saying it as she's beautiful and I would want you to be bugged by it - we had a Raid 41 dinghy that the internal cockpit well straighlined in several parts by the builderand it bugged me, it could have been curved and looked better. Great builders, great boat, great choice.

[Dave Lesser]

shouldn't that crane's straps also have athwartship steel bars accross the straps to prevent compression loading the hull, especially as she doesn't have a deck yet?

I can't speak to the actual engineering, but these cold-molded hulls are incredibly strong and rigid. Although there is no deck, some bulkheads had been installed prior to the turn-over. I would bet that this hull could be laid on its side (even without the bulkheads) and the beam would be compressed by less than 1/2".

the only straight lines I can see are those two straight pieces forming the aft bottom of the cockpit well

Good point. This is just the framing for the seats. The actual seats will be contoured. Thanks for your comments.

[keyhavenpotterer]

Actually looking at it with the wheel, there's probably a bit more room for one's toes as you walk around the cockpit wheel as drawn, below the curved seat tops as you go forward. Also the slight lip may be good to put your toes under to brace sometimes. Also a flat surface is better to mount the engine controls and instruments if they're mounted there by the helmsman. Yep stick to the plan. Mr Gartside knows best.

Out of interest, and I know she's not finished yet but are the professional builders building her in the time (in man hours) Paul estimates or quicker or slower?

[Peacefuljourney]

Out of interest, and I know she's not finished yet but are the professional builders building her in the time (in man hours) Paul estimates or quicker or slower?

Paul estimates are purely just a random number. The design I am building (Carvel plank) he said 5000 hours, but the same boat with the same lines build strip plank with 2 layers of veneer on top also said 5000 hours which is already LOT'S of more hours then carvel.

You can't estimate time, too much variable.

[peter radclyffe]

Paul estimates are purely just a random number. The design I am building (Carvel plank) he said 5000 hours, but the same boat with the same lines build strip plank with 2 layers of veneer on top also said 5000 hours which is already LOT'S of more hours then carvel.

You can't estimate time, too much variable.

Paul estimates are purely just a random number, can you explain, is this tombola or bingo

[Peacefuljourney]

Paul estimates are purely just a random number, can you explain, is this tombola or bingo

Pretty much yeah Well as you know choices can change a lots the number of hours examples:
1)You can find veneer the exact size you want, or you have to trim them out.
2)The glue bought can change the way you need to prepare the surfaces.
3)You buy already made bolts or make them yourself
4)You are alone during the building or with someone.

Just those 4 one can double the time of construction. That's is without the kind of finish you gonna do on the boat.

[peter radclyffe]

so if the someone your with buys the bolts, & sniffs some glue & trimly prepares the veneered surfaces while clockwatching
how long does it take
and how does this compare with pardeys hours

[Peacefuljourney]

so if the someone your with buys the bolts, & sniffs some glue & trimly prepares the veneered surfaces while clockwatching
how long does it take

That also depend on other factor, as how much builders are on cocaine. Do you keep the coffee pot always full or do you pee on the job or go to the bathroom...

As I said too many factor to give a accurate time range for a boat starting just with the plan.

[Peacefuljourney]

As a example, if you go pee at the bathroom and it take 8 minutes everytime (The bathroom is far from my shop)... Well 3 times a day for 2 years. That's 208 hours spent on peeing... If you pee on the job you've saved 200 hours on the building!

[Dave Lesser]

Paul Gartside has built some pretty substantial boats himself, generally working alone, so I suspect that he would be able to provide a fairly accurate estimate of the time that HE would take to complete a project. But as PJ states, it is impossible to estimate how long it would take someone else, especially an amateur, to do the same work. Neither Paul Gartside nor Eric Jespersen's crew spend much time in the moaning chair.

Paul guestimates 10,000 hours for this boat on his website. It probably would have taken me 20,000 to build it myself, and the actuarial tables suggest that my heirs would have had to try to dispose of an incomplete hull.

It has taken Eric's crew about 4,500 hours to get to this point. I'd say we're on track to come in well under 10,000 for the completed boat.

[peter radclyffe]

thanks