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Thread: Stambaugh Sailing Skiff Build in Virginia Mountains

  1. #281
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Today, steaming and clamping the starboard chine log:

    starboard steamed resized.jpg
    "George Washington as a boy
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    He could not even lie."

    -- Mark Twain

  2. #282
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    For July 4th I was sanding the new chine logs.....

    sanding resized.jpg

    ....when life interfered.

    Flora, the Canine Shop Helper, appeared with a squirrel tail hanging out of her mouth. I tried to take it away from her, but she would not let go. All but the very tip of the tail went down the hatch.........

    squirrel tail resized.jpg

    SWIMPAL called the vet, who advised to induce vomiting by giving the dog hydrogen peroxide orally. No luck. Nothing was purged -- until 0530 this morning. Fortunately, the dog was OK and it was only a minor mess.

    Today I installed the new chine log on the port side. Still not perfect, but a much better fit than the first attempt. Stay tuned.

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

    -- Mark Twain

  3. #283
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    New starboard chine log installed. I'm finally figuring out how to make parts fit together and not make a mess with wasted epoxy.

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

    -- Mark Twain

  4. #284
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Chine logs and frames faired. The workmanship is still less than precise. Needed a little shimming here and a little planing there. Much better than the first attempt at chine logs.

    chines and frames faired resized.jpg

    Trimming the chine log hood ends:

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

    -- Mark Twain

  5. #285
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    In the bottom of a tool box, I found this oddity.

    versa mate resized.jpg

    It's called a Versa Mate, and it dates to ca. 1960. It appears to be a planetary gear system to increase the torque from an electric drill. The jury is still out on whether it is useful. When cranking down a big screw, the torque is too much to hold on to. Still, I think it will be useful in some applications.

    The Versa Mate has a chuck for 5/16" Yankee screwdriver bits. Since those bits are practically unobtainable, the tool's usefulness in its stock form is pretty limited. Fortunately, Highland Woodworking sells adapters that allow the use of standard 1/4" hex drive bits in the Yankee chuck.

    "Ol' Yeller," the DeWalt drill, came with a keyless chuck that I cursed every time I used it. Now it wears a keyed Jacobs chuck found at a thrift shop for $2. It also wears a new power cord, to replace the original that was held together with pink duct tape.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  6. #286
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Planking at last! The transom gets an extra layer of plywood, as reinforcement in case I want to add an outboard motor.

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

    -- Mark Twain

  7. #287
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    The outer layer of transom planking, without the clamps. Plenty of opportunities for filling screw holes and fairing.

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

    -- Mark Twain

  8. #288
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I used the lattice pattern to cut out a mockup of the side panels. Make mistakes on cheap underlayment, not expensive marine plywood.

    The Ugly Green Shelf in the background was a discard long ago from work at the toothpaste tube factory. I almost sent it to the landfill when we built the garage, but even though it is rickety, it proved to be incredibly handy storage. The orange object in the center is a old cafeteria tray, bolted to a folding storage rack to make a bicycle mechanic's work station.

    mockup layout resized.jpg

    mockup resized.jpg

    The trial fit looks pretty good, and will require minimal tweaking. It's really starting to look like a boat.

    trial fit resized.jpg
    Last edited by UCanoe_2; 07-25-2021 at 10:12 AM.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  9. #289
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Ripping the good, expensive plywood for side panels.....

    ripping resized.jpg

    .... and scarfing. Not perfect, but will be adequately strong.

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

    -- Mark Twain

  10. #290
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Using the lattice pattern to lay out the "real" side panels. Forward and aft halves are temporarily fastened together, but will be installed individually. I will most likely be working without a helper, and want to minimize the amount of epoxy on my clothes.

    layout lattice resized.jpg

    And cutting out the side panels.

    cutting out resized.jpg

    Trial fit of port quarter panel. It will need some trimming at the transom, but otherwise fits exactly. This really feels like I am making progress now!

    port quarter trial fit resized.jpg

    The picture below is an accident, previously shown in #288, and IDK how to delete it.
    Attached Images Attached Images
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  11. #291
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    The scaffold deserves an honorable mention. The planks are 2 inch thick black locust. I originally planned to use one for the stem, but the grain is too wonky. They might some day become benches, or part of a trailer flat bed. Now they are supported on two milk crates, a weight lifting stool scrounged from the county dumpster, and two worn out boat trailer tires. Never throw anything away!

    Attachment 91452
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  12. #292
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I neglected to mention in this thread that on Tuesday I brought home a new Road King trailer. See my trailer thread at http://forum.woodenboat.com/showthre...-King-trailers

    I am now pondering whether to increase the trailer load by adding a flatbed, or softening the suspension by modifying springs. Stay tuned.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  13. #293
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I started wondering if the outer stem was going to fit properly after the planking is in place. It's time for a little compass and straightedge geometry. This fun and useful skill is often neglected in school math classes these days, in favor of memorizing boring formulas. Apparently this misguided pedagogical method is driven by the Standards of Learning, or SOLs. We all know what SOL means in the army, and no doubt the students feel the same....

    First, laying out a baseline on scrap plywood:

    baseline resized.jpg

    To measure the angle of the boat's bow, we strike an arc centered on the point of the stem and intersecting the chine logs:

    fingers resized.jpg

    Now we can use this measurement to lay out the bow angle full size.

    angles resized.jpg

    Let alpha = bow angle, then beta = bow half angle.
    Theta = 90* - beta
    Theta is the angle of the plank edge at the face of the outer stem.

    (It's too late to figure out how to make the Greek keyboard work.)
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  14. #294
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Setting the bevel gauge to angle theta. The bevel gauge will be used to set the bandsaw to cut sample pieces of planking.

    little bevel gauge resized.jpg

    While cutting the sample planks, my attention was distracted by a broken bandsaw blade, and the photo shoot sequence was interrupted.

    broken blade resized.jpg

    But eventually the sample planks got cut out and attached to the stem.

    temporary plank resized.jpg

    The outer stem is 1-7/16" thick. The whole purpose of this exercise was to make sure the finished planks would not protrude past the sides of the outer stem. It looks like there is room to spare.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  15. #295
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    Default

    This is great progress. I’m excited to see the planks put on.


    Sent from my iPhone using Tapatalk

  16. #296
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Thanks, Old Guy, I am excited too. port side planking.jpg Yesterday I made the trial fit of the forward half of the plank on the port side. I am having computer difficulties at the moment, so not sure if the picture will show up.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  17. #297
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Well, I accidentally locked myself out of the computer for a few days.

    While posting the geometric formulas in #293 and #294, I changed the keyboard language from English to Greek. The Greek letters did not show up while I was posting, so I thought the change did not work.

    At least that's what I thought until the next time I tried to log in. Sure enough, the keyboard language was indeed set to Greek, and my English password did not work. It took a few days to diagnose and fix this problem.....
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  18. #298
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    It sure helps to have a friend with a Type A personality. Antonio came over yesterday, and we installed the port side planking for real:

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

    -- Mark Twain

  19. #299
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    This boat requires gains, both forward and aft, so the sheer strake will blend into the planking. I laid out the gains on the plywood and cut them with a rabbet plane. Photos of that operation seem to have disappeared, but you can see the result for the port side planking above.

    But, I goofed and cut the gains for the starboard side on the inside surface of the plywood, rather than the outside.

    gain goof resized.jpg

    This error was not too difficult to repair. I sawed along the edge of the rabbet, then epoxied a strip of glass tape across the joint. I clamped the repair with a couple of builder's shims to wedge the gain into the proper shape. There is some cleanup to be done, but this will be a pretty good recovery.

    gain repair_01 resized.jpg

    gain repair_02 resized.jpg

    Soon I will be able to install the port side planking.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  20. #300
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Woo-hoo! Starboard side planking is installed!

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

    -- Mark Twain

  21. #301
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    You may remember that back in post #274 I made a lattice pattern for the chine logs. Then I copied the pattern onto a couple pieces of scrap from resawing the ash. I used the materials from the lattice pattern to make a new pattern for the side panels.

    The sheer strake pattern on the scrap was too stiff to follow the curves of the boat. So, I am copying them again onto pieces of thin underlayment. I screwed the underlayment onto the scrap pattern with brass screws. Hopefully, this will minimize damage to my saw blades when I cut out the new pattern.

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

    -- Mark Twain

  22. #302
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Life has intruded again. Some of you may have seen my thread about the melted canoes. http://forum.woodenboat.com/showthre...-Melted-Canoes
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  23. #303
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    As usual, progress is two steps forward and one step back.

    Last week, we installed the plywood planking on the starboard side with screws and epoxy. Come to find out, the epoxy on the aft half of that planking did not cure properly. It is still soft enough to stick a toothpick into:

    toothpick resized.jpg

    I thought I could simply remove all the screws, scrape off the defective epoxy, and apply new. Except I can't get all the screws out. I used bronze screws below the waterline and up the corner of the transom. I used stainless screws above the waterline.

    The stainless screws came out handily. Unfortunately, I was only able to remove three of the bronze screws. The rest would not budge.

    Aha! I will try heating the remaining bronze screws and see if they will come out.

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

    -- Mark Twain

  24. #304
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    My doctor says boatbuilding prevents dementia by requiring us to solve complex problems. If that is true, I will have great cognitive functioning beyond the grave.

    Guys, what are your thoughts about this development?

    By heating the screws, I was able to remove all of them from the planking with soft epoxy. Thinking to scrape off all the bad epoxy and replace it with good, I started prying the plywood away from the frame. That is, until I heard the sound of plywood delaminating.

    wedges resized.jpg

    Even though it is not properly cured, the bad epoxy is pretty tenacious. So what's the solution?

    Cut through the joint with a hacksaw blade, hot wire, etc.?
    Drill a series of small holes and inject additional hardener, in the hope that the epoxy will then catalyze completely?
    Put all the screws back, and consider the soft epoxy to be just a caulking compound?

    Your advice will be appreciated.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  25. #305
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    I'm not an experienced boatbuilder, by any means, but I'd think that since you've started to remove the panel, it's best to get it off completely, clean up the half-hardened goop and start again. Whether the panel is salvageable probably depends upon how much it started delaminating. Any voids will be places for rot to set in, so I'd replace it unless you can relaminate the plies that started letting loose. Maybe a heat-gun would help loosen it enough so that you could continue working your way around the panel with wedges until you can peel it off? Good luck! That's about all I got, sorry.
    --------------------------------------------------------------------------------------------------
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    The only man who makes no mistakes is the man who never does anything."
    Roosevelt, Theodore

  26. #306
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Thanks, Ed. The delaminated area is small, about 1" x 2". I stopped as soon as I heard something cracking. It can either be glued back together, or a patch scarfed in. No need to replace the entire panel.

    Besides, the forward and aft halves of this side are now firmly scarfed together. Of course, the forward piece overlaps the aft, which would make it more difficult to remove the aft piece. So the plan is to leave the forward half in place, and only loosen the aft part enough to scrape away the bad epoxy.

    The heat gun is worth a try, but the glue joint that needs to come apart is pretty well insulated by the chine log. Hopefully disassembly can be accomplished by proceeding slowly and gently with heat and wedges. A hacksaw blade may come in handy.

    I may not have time to work on the boat again until Saturday and Sunday, so stay tuned.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  27. #307
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Scarfing in a new piece sounds like a good idea, if you can't otherwise repair it. I agree. No need to replace the entire panel. Will it be fiberglassed? That will also help strengthen the panel and prevent water intrusion.
    --------------------------------------------------------------------------------------------------
    "
    The only man who makes no mistakes is the man who never does anything."
    Roosevelt, Theodore

  28. #308
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Yes, it will be glassed at least at the chine and probably up the entire side. The damaged plywood is right along the chine. I will have a better assessment once the whole panel is unglued.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

  29. #309
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    After unsuccessful attempts to cut through the bad epoxy joint with hot tools, I tried saws. They didn't work well, either.

    The Sportsman's Pocket Saw wandered badly....

    pocket saw resized.jpg

    ...and the hacksaw blade was painfully slow.

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

    -- Mark Twain

  30. #310
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    Default Re: Stambaugh Sailing Skiff Build in Virginia Mountains

    Finally I consulted with Jamestown Distributors tech support. The guy at Jamestown agreed that I had an epoxy mixing problem, and thought I might find a mixture of hard spots and soft spots.

    He suggested I try cutting the bad glue joint with an oscillating tool, and sure enough that is working. It's a nasty, messy job that includes getting a face full of sawdust. I got about 2/3 through today before supper time.

    wonder tool resized.jpg

    Tomorrow the remnants of Hurricane Ida will pass through, with rain in the forecast all day. It will be an ideal day for staying in the shop. I will finish cutting out the bad joint and prepare for re-gluing. Hooray!

    We are going to PA Thursday and Friday to pick up a replacement for one of the melted canoes. If I am speedy tomorrow, I can apply the epoxy and it will be cured by the time we return home.
    "George Washington as a boy
    was ignorant of the commonest
    accomplishments of youth.
    He could not even lie."

    -- Mark Twain

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