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Thread: Stambaugh Sailing Skiff Build in Virginia Mountains

  1. #316
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Looks good! Nothing better than a pile of shavings.

  2. #317
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    My wife thinks that is a pile of mulch.

    It took a while to learn to operate the compass plane, but now I like it a lot. Keeping it really sharp is important, of course. But also, there is a complicated interaction between the curvature of the sole and the protrusion of the iron. It requires constant tweaking, especially on a workpiece like this stem with changing curvature.

    The outer stem turned out to be a bit narrower than the width of inner stem + planking at the forward end. It will need ~1/8" pieces applied to both sides. I'm thinking about black locust.

    Thanks, guys, for all your encouragement!
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  3. #318
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    To bevel the chines, my boat buddy Antonio had the idea of attaching a batten parallel to the chine and using it as a guide for the circular saw. Oops, this was not a productive idea because the circular saw did not tilt in the desired direction.

    So, it was time to use the power plane. This looks to me like a tool that could remove fingers in a heartbeat. But, there is a lot of planking and chine log to trim away, so a power tool is in order. The unnecessary batten to guide the circular saw is still attached.

    power plane resized.jpg

    After a while, it seemed like a good idea to switch to hand planes for more precise control.

    hand planes resized.jpg

    The chines are almost level, but I will need another session with the power plane and further refining of the shape with hand planes.

    almost level resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  4. #319
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I cut the stem too soon and too short, so I built up the forefoot with a 5/8" thick piece of black locust.

    locust forefoot resized.jpg

    Next work session I will finish planing the chines. It's getting cold in the shop and the epoxy is really hard to pump. Time to use the epoxy warming cabinet again.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  5. #320
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I have not posted for a while, but have not been idle.

    Building up that forefoot with black locust was a good idea, but that stuff is really hard to plane -- especially the area with the little knot! It's almost the right shape, but I will have to resort to the belt sander with 40 grit paper to complete this part.

    In the meantime, I laid out a pattern for the bottom planking on a sheet of cheap underlayment ply:

    bottom pattern resized.jpg

    I started planing the scarf for the bottom planking. I decided not to use the power plane. An hour's work with the two hand planes and the job was halfway complete. No need to go to the Y for an upper body workout!

    bottom scarf planing resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  6. #321
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I hate to admit it, but I have some 40 and 80 grit paper in my workshop. I guess they make it for a reason! LOL

  7. #322
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Quote Originally Posted by dalekidd View Post
    I hate to admit it, but I have some 40 and 80 grit paper in my workshop. I guess they make it for a reason! LOL
    There have to be alternatives to brute force tools like angle grinders. Thanks for following this thread, Dale.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  8. #323
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Quote Originally Posted by UCanoe_2 View Post
    There have to be alternatives to brute force tools like angle grinders. Thanks for following this thread, Dale.
    Us Virginians have to stick together!!

  9. #324
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Cutting out aft bottom plank:

    cutting bottom plank resized.jpg

    Aft bottom plank trial fitting:

    bottom aft trial fit resized.jpg

    Made a gauge from scrap for marking bottom screw holes.

    marking gauge resized.jpg

    And, trial fit of forward bottom planking. I will need to tweak the scarf a bit to get everything fair.

    fwd bottom plank trial fit resized.jpg

    My boat buddy Antonio says the boat almost looks like she would float now. I had to point out that the boat is wood, and would float even without the bottom...........Of course, she would not float on her lines..........
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  10. #325
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Major boatbuilding progress today! My friend Raz helped me install the bottom planking.

    Raz applied epoxy to the chine logs while I pondered some abstract boatbuilding problem:

    raz_epoxy.jpg

    We carried the primed aft bottom panel out of the garage bay.

    raz_primed_panel_resized.jpg

    Two old guys trying to turn over the sticky bottom panel without getting epoxy on themselves.

    raz_turnover.jpg

    Fortunately, in a stroke of genius we had attached pieces of scrap lumber to be temporary handles for the panel.

    raz_handles.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  11. #326
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    And we carefully lowered the panel into place.

    raz positioning.jpg

    I had previously fitted the panels and drilled all the necessary screw holes. We used awls to align the holes in the panel with holes in the chine logs.

    raz_awls.jpg

    Raz placed the screws and I tightened them.

    raz_screws.jpg

    We installed the forward panel the same way. The boat now has a bottom!

    raz_bottom.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  12. #327
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Feels good when the boat comes together like that! WTG!

  13. #328
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Thanks, Dale. Plus, I have a happy spouse since the temporary work station for making large boat parts has been moved out of her side of the garage!
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  14. #329
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Of course the bottom panels were oversized and needed trimming. I started with a router and a straight flush trim bit.

    router_straight resized.jpg

    The straight bit removed most of the excess plywood. I needed a rounded edge to hold fiberglass, so I switched to a 3/8" roundover bit.

    Router bits are designed by engineers who think only in terms of plumb, level, and square surfaces. So even after trimming with the roundover bit, there was still 1/16" to 1/8" of overhanging plywood to remove.

    router_roundover_01 resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  15. #330
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    What to do? Digging through my drawer of router bits, I found one with a pilot bearing smaller than the rest.

    router_bits_resized.jpg

    Some measuring confirmed that installing the small bearing on the 3/8" roundover bit would allow trimming the plywood just about the right amount. Time for a bearing transplant.

    router_bits_disassembled_resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  16. #331
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Except...more measurement confirmed that the ID of the small bearing was about .0025" smaller than the ID of the large bearing. How to make a smaller bearing fit a larger shaft?

    I heated the small bearing on a 100 watt flood lamp...

    router_bit_bearing_floodlight_resized.jpg

    ....and put the 3/8" roundover bit in the freezer. Frozen lima beans are an important element of this procedure. If you try this at home, do not omit the lima beans.

    router_bit_limas resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  17. #332
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    After 45 minutes of heating and cooling, I used the drill press to install the bearing on the roundover bit.

    router_bit_drill_press resized.jpg

    The bearing went on far enough to enable me to install the retaining screw. I ran the router with the bit installed for 30 seconds to make sure nothing flew off. I also wore appropriate PPE.

    The resulting rounded edge is OK, but will require sanding and/or planing to clean it up.

    router_edge_better resized.jpg

    I dunno if the transplanted small bearing will come off the roundover bit. It may be permanently installed with a heavy interference fit -- stay tuned for further developments.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  18. #333
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Quote Originally Posted by UCanoe_2 View Post
    The resulting rounded edge is OK, but will require sanding and/or planing to clean it up.
    Very creative! I simply went with the belt sander to round over my edges. It's amazing how quickly coarse grit will take off wood, especially on a corner. It might not be perfect, but it was pretty good.

    build28.jpg

    Now on my current build, I did use a router on my daggerboard trunk. The corner is square so no problem and a belt sander wouldn't fit LOL. I needed that edge to be round to take the fiberglass.

    Not the best picture but you get the idea. (ignore the white fill - that was from a "repair" I made after a mistake on the trunk installation).

    IMG_6526.jpg

  19. #334
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Well, Dale -- "the perfect is the enemy of the good." Or, in many cases, the enemy of the "done."
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  20. #335
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    In between coping with an 8-9" snow storm, wondering about backordered furnace parts, cursing wet/green firewood, clearing the 600 foot driveway for the propane truck, and varnishing snowshoes, I managed to fit in a little boatbuilding time.

    Time to build the keel. The keel on this boat is just a simple plank.

    Because of the curve of the bottom, the stations are not exactly 36" apart on the plank, as they are in the plans. To accurately mark the station lines on the plank, I laid it on the upside-down hull and weighted it with chunks of 2" thick steel from the "It's Gotta Be Useful Someday" collection.

    keel with weights_resized.jpg

    I took off half breadth dimensions from the lofting. Then I struck a centerline on a 1x8 (nominal) yellow pine plank, and used a batten to lay out the outline of the keel.

    The centerboard case is at left in this photo. Somehow it got stretched to 1-1/2" longer than the dimension shown in the plans. The aft end of the CB case is supposed to fall exactly at the #3 station line, so the front will be 1-1/2" further forward than designed. No big deal, I think.

    keel layout_resized.jpg

    Cutting out the keel with the circular saw. I was able to stay very close to the lines, and minimal dressing with a plane was required. I also cut a long notch in the aft end to fit the skeg.

    keel sawing_resized.jpg

    Then I eased the edges with the router and 3/8" roundover bit. For those who were in suspense about the bearing swap in #330-332, the small bearing did not get stuck. It was easy to replace the stock pilot bearing on the roundover bit.

    keel router_resized.jpg

    That's it! The keel is complete, ready for final fitting and trimming, and installation on the boat.

    Thanks to SWIMPAL, who graciously loaned "her" side of the garage for boatbuilding operations this afternoon.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  21. #336
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Quote Originally Posted by UCanoe_2 View Post
    After 45 minutes of heating and cooling, I used the drill press to install the bearing on the roundover bit.
    Wonderful! Cleverer than the belt sander... (in addition to belt sanders... I may have also resorted, once, to a sanding disc on an angle grinder... which made the belt sander seem like a precision hand tool).
    Daniel

    Building a Campion Apple 16.

  22. #337
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Thanks, Daniel. Every once in a while I have a good idea.

    Love your boat! You have a lot of fortitude to work in an unheated garage in Boston!
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  23. #338
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Quote Originally Posted by UCanoe_2 View Post
    Love your boat! You have a lot of fortitude to work in an unheated garage in Boston!
    Thanks! It helps that I rarely have more than an hour at a time... which is usually short enough that only my fingers are starting to get cold, even when it is quite cold.
    Daniel

    Building a Campion Apple 16.

  24. #339
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Daniel, I'm a big fan of fingerless gloves. They keep my hands warm, but also add protection against splinters and skin tears.

    fingerless resized.jpg

    Fitting the keel. It will be screwed to the frames with 1-1/2" #12 screws, and to the bottom planking with 1" #8 screws. And epoxy, of course. I am installing stainless screws when trial fitting, but below the waterline the final fasteners will be bronze.

    keel trial fit resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  25. #340
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Quote Originally Posted by UCanoe_2 View Post
    Daniel, I'm a big fan of fingerless gloves. They keep my hands warm, but also add protection against splinters and skin tears.

    fingerless resized.jpg
    I definitely rely on them in the winter -- though mine are fleece lined & wool -- I hadn't thought about lighter weight ones for general use though, that's a good idea.
    Daniel

    Building a Campion Apple 16.

  26. #341
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I have a nice piece of Philippine mahogany just the right size for the skeg. Scribing to match the curve of the boat's bottom. Pattern for skeg in foreground, taken from lofting.

    skeg_scribing resized.jpg

    Trial fitting the skeg.

    skeg_trial fit resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  27. #342
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Now it is time to contort my no longer young and limber body, and crawl under the inverted boat. The skeg is held down by ratchet straps, and aligned plumb by blocks of scrap lumber. I'm drilling from underneath, and installing screws to attach skeg and keel to bottom plank. Temporary steel screws come first, then they will be removed and parts will be attached with bronze screws and epoxy.

    skeg straps resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  28. #343
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Remember when you were a kid and got bubble gum in your hair?

    Remember how your mom had to chop it out and give you a really horrible haircut?

    When we are grownups, we can do the same thing with epoxy. Even when we have very little hair. It's a bit more expensive than epoxy, but the haircut is just as bad. The goop gets on your clothes too.

    That's what happened yesterday when I was crawling underneath the boat installing the keel and skeg. Seven big screws went into the keel from above. Eight or ten big screws for the skeg, plus about 30 little screws for the keel, were installed from below. Of course, all the while epoxy was dripping from holes that had not yet been plugged.

    Yep, it was another one of them learning experiences. I've figured out a way to fix this problem, but you will have to wait until I install the centerboard case to see the solution. And if any of you have suggestions please post them, 'cause I'm running out of hair.

    No photos of the mess in progress, but here is the result.

    keel and skeg installed_resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  29. #344
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I'm not sure I understand why you are using screws. I would think the epoxy would hold. I don't have a keel plank like you do, but I do have a skeg. I simply epoxied it into place. I can't imagine that it won't hold.

    IMG_6854.jpg

    with a nice fillet added

    IMG_6856.jpg

  30. #345
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Nice lookin' boat, Dale! How did you get your skeg to stay plumb while the epoxy was curing?

    Glue and screw construction is what the designer specified. Belt and suspenders, you know. This is one of Karl Stambaugh's earlier designs (1995). It may be that he did not completely trust epoxy back in the day. Also, some of my workmanship is not the greatest and joints did not fit well. More epoxy will be added to fill them in later stages of the build.

    BTW, if anybody is thinking about building this design, Karl offered to re-draw it for stitch and glue but said that would take a few months. I was impatient to get started and declined the offer. You might want the redrawn plans.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  31. #346
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Quote Originally Posted by UCanoe_2 View Post
    Nice lookin' boat, Dale! How did you get your skeg to stay plumb while the epoxy was curing?
    I cut out the skeg on my band saw and just figured the cut was square; so I simply lathered it up with some thickened epoxy, set it in place and put a little weight on it. The fit was pretty good and presto! The skeg is 1" wide so was stable just sitting on the hull.

    PS: I went back and looked at my last build from 10 years ago. Looks like I had to prop up the skeg on that one. I took a little pail of something, no doubt with a little weight, and set it up next to it. It would have to be something that epoxy wouldn't stick to.

    build118a.jpg
    Last edited by dalekidd; 02-02-2022 at 11:54 AM.

  32. #347
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I attached 3/4" thick skeg with just epoxy and some fillets and have had no problems. The cut from the bandsaw was square and a temporary screw kept it from sliding off the back while it cured.


  33. #348
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Thanks, guys. You have remarkable confidence in the ability of your saws to make square cuts, and in the ability of parts to remain properly oriented when you balance weights on top of them.

    I cut the hull side of my skeg with a brand new Ryobi sabre saw, which did not cut square right out of the box*. I had to dress the faying surface with the compass plane.

    I also cut a slot or mortise in the keel, into which the skeg fits. Theoretically this construction is a bit stronger than relying only on glue. Belt plus suspenders.

    *The Ryobi is OK now after some adjustment. (It replaced a 40 year old Sears saw, for which repair parts were unavailable.) So far it looks like a pretty good saw. It has a dust collection port, which is an important feature for me. I just wish Ryobi tools came in another color besides fluorescent monkey vomit chartreuse.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  34. #349
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Cutting centerboard slot in keel, using circular saw with homemade guide.

    keel CB slot_resized.jpg

    Golf tees mark pilot holes for centerboard case screws. When I glass the bottom, I will pull the tees out, wax them, and replace them.

    keel golf tees_resized.jpg

    More fitting of the outer stem.

    outer stem fitting_04 resized.jpg
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  35. #350
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Still more fitting of the outer stem. Parallel is more important than plumb, level, and square.....right? Too late to fix now. The little aluminum level I chopped up with the Sawzall way back when was the source of the problem, and not all the error came out. It's hard to see unless someone has a really good eye. I doubt it will make any difference in the performance of the boat.

    outer stem fitting_05 resized.jpg

    Trial fitting rudder hardware. It turns out there were a bunch of holes to drill prior to glassing, more than I anticipated.

    gudgeons resized.jpg

    The 1/2" hole with fresh sawdust below the lower gudgeon is for a rudder retainer. I'll fill this hole with epoxy, and then re-drill a 3/16" hole for a #10 machine screw.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

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