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Thread: Building the revised Gorewood 16' Canoe - second attempt

  1. #1
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    Default Building the revised Gorewood 16' Canoe - second attempt

    Almost a year ago my first attempt failed dramatically: http://forum.woodenboat.com/showthre...end&highlight=

    Before starting the next try I need to get rid of last year's sad remains:





    Last edited by flo-mo; 04-10-2017 at 11:52 AM.

  2. #2
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Comparison of the thickness of the veneers of the okoume plywood I used last time that did not survive the torture of the building process and the poplar plywood I am using for the hopefully successful new build.



    So yes, it is poplar plywood again -- this time 4 mm for the 16' canoe as opposed to 3 mm I used for the two smaller Gorewood Canoes (12' and 14').

    For this building method ideally the thickness of the core veneer should equal that of the face veneer, but I hope this is close enough. At least this poplar plywood is way more flexible than the okoume was.

    The drawback of the plywood sheets I have is the quality of the veneers.

    One face is full of knots and while the other face looks good at first glance a close inspection reveals cracks carelessly filled with brittle putty.
    Luckily the sheet is larger than the standard (252 x 172 cm as opposed to 244 x 122 cm) so I was able to find a layout for the panels avoiding most of the major flaws.
    The photo shows the side with the knots. This side of the panels will later be at the inside of the hull.



    The procedure of the build is very much the same as the at length documented failed attempt (https://plus.google.com/u/0/photos/1...40662359105329).
    So I will skip most of it and only show what is different (especially the part when hopefully this time everything comes together without any disaster).

    Panels cut and arranged with the apparently good side up (this side will be at the outside of the hull):



    I stabilized the knots and filled the few remaining cracks with epoxy.



    The rotary-cut veneers of the poplar plywood have a weak part in the annular growth rings which is softer than the rest. I also saturated these areas with epoxy because that's where the plywood is prone to crack when being "tortured" in the building process as I learned the hard way in a previous build.




    After all these measures to cope with the imperfections of the plywood it is time to move forward with the actual build.
    Last edited by flo-mo; 04-10-2017 at 11:59 AM.

  3. #3
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    I am looking forward to seeing how this project turns out.Your last canoe had the potential to be very good looking and so nearly worked out.

  4. #4
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    I was curious about how much that plywood might weigh. I could only find a spec for the density, as applied to all sheets, of whatever thickness. According to my calculations, a sheet of that plywood is about 5.4 kg? Less than 12 lbs? That is crazy light.

    http://europlywood.com/catalogue/poplar-plywood/

  5. #5
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    It is my intention to keep the total weight of the canoe under 20 kg (44.4 lbs). So the light weight of the poplar plywood is an advantage. The panels of this build weigh 8.5 kg (at 19 lbs) whereas the okoume panels were about 10.4 kg (at 23 lbs).










  6. #6
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    This time it was more difficult to close the outermost gores.

    To get this job done I used a special device made of a disassembled hinge.












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    Default Re: Building the revised Gorewood 16' Canoe - second attempt












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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Installing the first half of the inner gunwales





    At this stage the two panels get permanently connected with glass tape.
    At first at the inside, then at the outside:







  9. #9
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt



    Removing the peel ply and also the masking tape





    Plugs for the stop drill holes





    Reinforcing the edges of the gores with filament tape


  10. #10
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Very interesting.

  11. #11
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    I am not sure if placing the filament tape is a good idea, but at least it looks interesting.



    Time to replace the spacers by the lashing straps again.







    The projecting part of the gunwales was useful while installing them, but is not needed any longer.
    Cut at 13.5 will be about right to connect them later in the process. An exact fit will also be done later.



    Last edited by flo-mo; 04-29-2017 at 02:32 PM.

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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Next comes the make-or-break part of the build.
    By tightening the lashing straps the hull is taking its final shape.

    I was so much focused on the process that I forgot to take photos of each step. I do not mind because more importantly so far everything just went fine and it seems this crucial phase was a success.













    I am not absolutely convinced to be on the save side as the stress of the tortured plywood may still lead to some sort of damage, but so far this build is clearly working out better than the last one.
    Last edited by flo-mo; 04-10-2017 at 11:14 AM.

  13. #13
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    You are the master plywood torturer of the world!

  14. #14
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Okay. I just watched that happen, but I still don't believe it.

    Well, I guess I have to believe it, but no way will I ever understand it.

    Excellent!

    Peace,
    Robert

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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Awesome, looking forward to more. Thanks for sharing.

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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Quote Originally Posted by Al G View Post
    Awesome, looking forward to more. Thanks for sharing.
    Get out of my mind!

    Awesome , can't wait to see more.

  17. #17
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    That...was...awesome....nicely done. Its all down hill from there.

    CG

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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Stefan - impressive, as usual.

    How long does it take to tighten up the straps? Is this accomplished a bit slowly to allow the panels to achieve their curvature? Do you apply any heat or moisture to help with the process?
    "The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails."
    -William A. Ward



  19. #19
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    WOW

  20. #20
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Quote Originally Posted by Canoez View Post
    Stefan - impressive, as usual.

    How long does it take to tighten up the straps? Is this accomplished a bit slowly to allow the panels to achieve their curvature? Do you apply any heat or moisture to help with the process?
    In this video it takes about two minutes to tighten up the straps :



    In real time it is a procedure that takes about one hour or maybe two because of me constantly watching if any cracks would occur and always checking for any miss-alignments.
    During this process I was very sensitive to any suspicious noise that even remotely sounds like cracking.

    It is crucial to tighten each strap one tiny bit at a time to avoid unbalanced pressure. While heat or moisture would certainly help to bend the plywood more easily, I passed on using either to keep the bending characteristics of the plywood uniformly. Luckily this time I had no problems so far and I really hope everything will keep working out.

    The photos in the video are a most welcome by-product of a friend who visited me in the workshop to create one of his cool panoramic images -- this time of my canoe build.
    You can check it out at his website: http://www.rundumadum.at/
    Last edited by flo-mo; 04-20-2017 at 09:35 AM.

  21. #21
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Great to see that this time it worked.

    I guess when exploring the outer limits of design possibilities it depends so much on the type of plywood and it is very helpful to see which types of plywood will and which ones will not work.

    Over the winter I started building a little 8' boat for my 3 year old nephew (my own "butterfly" double ended dory skiff design, slightly larger than your babyboat) and I was very impressed how well the 4mm marine okoume ply I was using took the bends at the bow. I wasn't sure it would, so I when pulling the boat together I was nervous and was also listening very hard for any slight sound of cracking (I didn't hear any, nor did I tear out any stitch holes).

  22. #22
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Hi BOI,
    I remember that you mentioned you were working on that little skiff. Is there a chance to see any photos of your project?

    Cheers
    Stefan

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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Wow. Anxious magic before my very eyes. I watched the last of these incredible experiments, and the level of detail is nigh unbelievable. Hephaestus himself could not have created a more singular, delicate process. Thank you, Dan

  24. #24
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    VERY nice!
    The best helping hand you will ever receive is the one at the end of your own arm.

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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    AWESOME !!
    Thank You for taking the time to document your painstaking process.


  26. #26
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Hi Stefan,

    The boat one I'm working on now is a new one, smaller than the one in the previous thread. I started a new thread so this one doesn't drift away from your wonderful canoe.
    http://forum.woodenboat.com/showthre...-little-nephew

  27. #27
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    The link to the photo-journal of the build : https://goo.gl/photos/MWCVLV3hWnpxKiPd

    For the thread I only use a selection of the large number of photos.

    After cutting the projecting ends of the inner gunwales they don't quite fit where the meet.



    A little sanding ...


    ... to achieve a tight fit:


    Preparing strips of plywood which will create a neat definition of the fillet at the bow.


    Strips installed and covering most of the fillet


    The clamps are holding the panels together until the fillet is cured
    Last edited by flo-mo; 07-19-2017 at 09:04 AM.

  28. #28
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Awesome. Thanks for sharing.
    Stay calm, be brave....wait for the signs. Possibly precariously prevaricating.
    .

  29. #29
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Patches of glass for reinforcing and padding the inside of the gores.


    All patches attached, saturated with epoxy and covered with peel-ply.


    I sanded the edges where the bottom turns into the bow ...


    ... and applied glass tape to strengthen the area that always gets rough-handled the most.


    That's when I noticed this little crack that is luckily not too bad and an extra layer of glass should solve the problem.

  30. #30
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    One more time I want to emphasize this astonishing way of displaying my workshop by courtesy of a friend:

    http://www.rundumadum.at/images/ru/P...02_1407/t.html

    http://www.rundumadum.at/images/ru/P...01_1407/t.html

  31. #31
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    The inner gunwale consists of two strips of spruce (18 x 11.5 mm).
    The first one was installed after closing the gores in an early phase of the build. If the inner gunwale was made of one strip only installing at that phase would almost be impossible because of the tight bend.

    Now it is time to install the second one.

    Once again the straps are replace by spacers that keep the sheer at the right distance.


    Before actually gluing the gunwales in place I do a dry run to check that the length is correct and that they fit snugly.


    Then I prepare the strips for the gluing process. It is convenient to place them at the inside of the hull, then just pick them up and install them permanently.


    I took measures to prevent that the hull gets messed up with epoxy during the gluing process especially towards the end of the hull.


    Because of the dry-fit I was familiar with the procedure.


    The ends of the gunwales need a special treatment because that's where they are bend the most. Steam bending would be an alternative, but I got away without the extra effort by simply forcing them into place.
    Last edited by flo-mo; 07-20-2017 at 08:46 AM.

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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Because of the large number of clamps access to clean up the oozing out epoxy is restricted. So I decided to wait until the epoxy is cured.
    Using a plane I got rid of the epoxy and also of the small protruding part of the plywood between the gores, which did not take much effort.









    I am not fully satisfied with the sheer line, but it is not so bad either.

  33. #33
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    I am disappointed that although I gave much thought to avoid a specific peculiarity of this building method, namely a slightly hollow keel line, it did not turn out the way I was hoping for.
    It is difficult to notice but there is a deviation from a straight line of at 3 mm. This is not much, but enough to bother me.



    This is the same photo, but stretched in one dimension with the keel line accentuated which makes the deviation apparent.


    After much pondering what to do I decided to go for a radical action and cut open an almost perfectly fine hull without knowing if this measure would actually help or maybe even ruin the whole project.

    I was hoping that by cutting small slits along the keel line at the humps, the keel line would straighten out.






    Much to my relief the plan worked out without spoiling the integrity of the hull. By first cutting two slits about 0.5 mm wide and 60 cm long and then closing this small gap again, the humps came down by 3 mm which makes the keel line almost straight.

  34. #34
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    The keel line is not perfectly straight, but in comparison it looks much better and I can accept the marginal irregularities.

    Before:


    After:

  35. #35
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    Default Re: Building the revised Gorewood 16' Canoe - second attempt

    Nice

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