New Tools
Hello again to all who read my little blog.
The restoration of a 17' plywood powerboat. Visit My Workshop here.
Hello again to all who read my little blog.
Just a quick note here.
I worked in the shop just a bit last night. Some of my tools have been rusting. The tables on the band saw, as well as both drill press had much surface rust, apparently due to the cold weather, so I spent some time cleaning those up last night. I used a scotch bright pad on a die grinder for the majority of the rust and finished up by hand and coated everything with a very thin layer of machine oil.
Ever since I fired up the heater the rusting seems to have stopped. There are a few more tools yet to be cleaned.
I also spent some time looking at and thinking about the boat. I'll be laid off after the weekend and will have much time on my hands.
Hi to everyone who visits my little workshop.
It's been a long summer and I have much to tell. Unfortunately, there hasn't been any work on the boat. Summer brings warm weather and that means lots of work at the concrete plant where I work. If I have failed to mention earlier in this blog, I drive a concrete mixer for a living, as well as many other things around the plant like dump trucks, tractor / trailors, bucket loaders, the forklift, the skid steer and anything else that I can do. Warm weather means contractors want to pour concrete... and we've poured a boat load of it this summer, (ship load actually).
If you've visited this site before, you'll notice that the first slideshow to the left has a completely new set of pictures... and I've added a music video from one of my favorite artists... Kitaro. Hope you enjoy the music.
The pictures show some of the work that I did on my boat last winter... 2006-2007.
I'm looking forward to working on her again this winter while I'm laid off work.
Aside from working at the concrete plant, I've accomplished much in what little spare time I could salvage out of my days and weekends.
(I typically work 8 - 12 hours per day... 6 days a week).
(During the fall harvest I was working as many as 16 hour days and 7 days per week for about 8 weeks straight.)
Just a note... this is about the same time as last year when "Abbeygirle" came to live here with us.
THE WORK
As mentioned in the "Tuesday, May 1st" posting, I had started several flower beds for my wifes flowers, bulbs and bushes in the back yard. I also landscaped the front yard with much of the same. A real patio was in order as well so, I built a 13' x 17' patio out of Dutch coblestones. Two different size stones in three colors. This I did while working 12 hour days and staying outside as late as 10:30 PM... for a week with temperatures in the high 90s ! UFFDA !!!
Spring is here and I'm back to work full time. I've also started with the yard work. The boat is on hold right now... for awhile anyway.
My wife and I just bought this house less than a year ago and we would very much like to spruce things up a bit. A little landscaping is in order.
Well,,,,,,,,,,, maybe just a scosch more than a little. The yard hasn't had much care for a good many years and much of the previous efforts to landscape the lot have long since been forgotten so, a lot of work is in store. I've been working for several weeks on two particular gardens for my wifes flowers & bulbs located in the back yard. The soil is hard as a rock... and full of it too.... rocks that is.... full of 2" river rock (previous landscaping ideas long since ignored and forgotten about). I've had to remove hundreds of pounds of this stuff from a 15' x 4' section of ground. I did this by actually hand screening every ounce of soil down 12" deep. I then added about 2" of mushroom compost and spaded this in. Then I added another 1"-2" of peat moss on top of this and spaded this in as well. The result is a very nice rich potting mixture that will hold moisture and provide a wonderfull place for the wife to plant whatever she wants to. Last but, not least, a couple inches of organic mulch to cover everything... and we have a garden.
I've dug up and hauled off two truck loads of sod...
I've hauled in a truckload of organic mulch... two truck load of organic compost... several contractor sized bales of peat moss... 3 tons of mason sand (for the new patio to put the new patio furniture on).
So much work to do... I do admit though... I love gardening !
My wife also bought two large tomato plants ! Planted them in a large pot (24" dia.) that I set up for her. She also picked up a couple of bell pepper plants and put those in a couple smaller pots.
We have a very small lot with two out buildings so, sunlight is a factor that has to be considered with everything. This is why the vege plants are in pots... the most direct light is right on the patio... and we think that it will be cool to walk out the back door and pick a fresh tomato... next to the back door !
Abbeygirle, our outside cat (who the boat is named after), bit off a bit more than she could chew last night. Late in the evening, while we were relaxing in the back yard on our new patio furniture, she decided to run out into the street... she hit a car... or the car hit her ? Anyway, she has a fractured pelvis, and a good concusion. She is very lucky... and so are we. The wife has set her foot down and stated that Abbey can no longer go outside without a leash.
She was originally a stray and basically lived in my garage (the workshop). She has, in the past, always been afraid of the street and the cars so, I always figured that she could stay outside although, I knew that the street out front posed a real threat. She has become a part of the family though and we intend to make sure that this won't happen again.
More about Abbeygirle to come later.
I've been down for awhile. Seems like I must have worn out the 80 gig hard drive in this computer. Had to send the computer to the doctor and have the hard drive replaced.
Anyway... while it was out... I had to bend another board. Rather than remove my gutter's downspout again, I opted to go ahead and build a simple steam box. Wow, it works great to.
Nothing fancy here.
The hinged door is sealed with standard weather stripping and the box itself has dowel rod inserted throughout the sides to support the wood and allow the steam to surround the workpiece. 45 minutes to warm up the box and 45 - 60 minutes of steam and we have bendable wood.
I used the same heater and boiler set up as before. A really nifty little gadget. All was made out of scrap laying around the shop and even the hinge and weather stripping was salvaged from another project in the past.
As far as what I've been working on .............. I've been trying to finish up the fuel cells inclosure as well as the bracing for the floor above the fuel cell. I've also been filling holes... lots and lots of holes. Other than this, there's not much to report
I mentioned in a previous post how most people have a set of plans (drawings & instructions) to work from. Some do not have such plans to work from. I have found on a few occasions though, that a drawing was necessary. Drawings take an idea from one's mind and put it down on paper enabling a person to see how something is going to look. It can also enable one to see the different dimensions (side, top & front as well as 3-d). A drawing gives a worker the ability to apply measurements (dimensions) to his idea, there by making it possible to "test" it's workability. If your attention span is a bit short (for what ever reason) the drawing helps to keep your idea in focus too :).
I've been working on the fuel cell's enclosure again. Ever since I made the decision to locate the fuel cell in the cabin under the bed I've been concerned about a few issues like.... how will I design the enclosure..? how will it balance and support the weight (approx. 160 + pounds full of fuel) as well as the weight of two people in the cabin (on top of the fuel cell) and so on..?
New hatchway dryfitting.
Today, and the last few days, I've been able to work a bit on the boat. Not as much as I'd like though. Sometimes, it's just better to walk away for a time, which is probably what I should have done the other day when Mr. Murphy slipped in to visit. Things have been slow going all week.
New Bulkhead Dryfitting.
I have worked (on and off) on the hatch cover as well as the new bulkhead and today I've focused on the fuel cell incloser too. You'll see in the pictures that I've made a little headway... kicking and screaming all the while..... ;(
Fuel cell incloser roughed in.
Fuel cell getting a test fit.
I have constructed most of the lid for the hatch and it's looking fairly nice so far.
Sooner or later everything will come together and actually be assembled permantly... still have a ways to go though. I have to fabricate a dash as well as the seating (at least the supports for the seats), coat everything with CPES and then at some point soon after I'll be purchasing some sandable primer to apply to the entire inside of the boat... Hulls, Cabin sides, Beams, Bulkhead... the works. I'll have to have a good start on the dash and the seats before this can happen though. Untill next time..... :)
Shop safety.
No... I didn't hurt myself yesterday, and murphy didn't get me either.
Shop safety is always important. I'm sure that everyone's heard your supposed to wear safety glasses... blah blah blah... Well, I believe in shop safety. I can't swear that I ALWAYS put on my safety glasses when I fire up a saw but, I can say that I should! Safety glasses are really a must... one doesn't realize how important or sensitive his or her eyes are untill one or both of your eyes are damaged. Working in a machine shop many years ago, using diamond studded grinding wheels, I wound up with a piece of a diamond inbedded in my eye. This wasn't life threatening but, it did require a trip to the eye doctor to have it removed from my cornea. Sawdust, metal shavings, wood chips and splinters all pose a real threat to our eyes.
Loose clothing is a definite no no ! Jewelery (big rings, necklaces) is not smart either.
When using saws (bandwaw, table saw, jointers etc.) a push stick is always smart. When I first bought my band saw I wanted to play around with it, experiment cutting little things. One of the first things I made was a simple push stick to keep my hands and fingers away from the blade.
I can honestly say that many times in my life I've had to make due without the use of one or more of my fingers or a hand... even an arm ! (I still have both arms and hands as well as all 8 fingers and both thumbs). I've had 4 broken arms. I've also broke, cut, gashed, smashed and whatever else you can do to terrorize one's hands and didgets many times over in my life time. Trying to tie one's shoes is a real bummer with only one hand.
I keep a medicine cabinet in my shop (with a mirror) stocked with peroxide, bandages, gauze... the bare essentials to patch something up if needed, at least untill I can get to the hospital, if needed. The mirror is handy too. Even wearing saftey glasses, you are still going to get something in your eye once in awhile, especially when your on your back under the truck and looking up ..................................................
Yesterday was a disaster... more or less but, a disaster.
I was trying to re-fabricate the individual pieces that make up the hatch cover ( a completely new hatch) and could not make the simplest of anything without messing it up. The hatch face I made three times... this is just a piece of plywood approximately 5" x 24" rectangle shaped, nothing fancy... no bevels... or curves... or radius'... just a rectangle. Three times... :(
Today will be better and, I hope to finish the hatch cover pieces and move on to the bulk head.
Yesterday was a disaster... more or less but, a disaster.
I was trying to re-fabricate the individual pieces that make up the hatch cover ( a completely new hatch) and could not make the simplest of anything without messing it up. The hatch face I made three times... this is just a piece of plywood approximately 5" x 24" rectangle shaped, nothing fancy... no bevels... or curves... or radius'... just a rectangle. Three times... :(
Today will be better and, I hope to finish the hatch cover pieces and move on to the bulk head.
Ever have one of those days when you know that Mr. Murphy is lurking somewhere behind you watching everything you do, and he's making sure that you can't do anything right ?
Well, he's in my shop right now. It seems that I cannot perform the simplest of tasks today. I've messed up everything that I touch... Everything !
Yesterday, I installed the remaining floor braces and then the cockpit floor itself. The floor consists of two layers of 3/8" plywood. The plywood was completely treated (both sides as well as all edges) with CPES to prevent water damage, and it will surely see it's share of water. The first layer was layed out and stapled with galvanized 1/4" x 1 1/4" crown staples basically at the corners and centers of each side to keep it flat until the second layer could be layed out and fastened. Each layer consists of two pieces of ply... one fore (running the full width of the floor) and one aft (likewise). Each seam is positioned directly above a brace. The seam on the first layer is positioned forward of the center (athwart ship) of the floor while the seam of the second layer is positioned aft. The second layer is secured every 5" all the way around each piece with SS #8 1 5/8" screws predrilled and counter sunk.
In the very back, the first 15"-18" forward of the transom is a separate piece of plywood (single layer) left unattached for access to the bilge. This piece will eventually have holes cut into it on either side of the keel for bilge pumps. The keel is solid (no holes connecting the bilges) so a separate pump for each side is necessary. This is also where the batteries will be mounted, one on each side, to the outside near the hull.
Now that the floor is in, I can grab my trusty bucket (an upside down seat) and start to heat and dig out the epoxy plugs on the cabin sides to tighten them up. There are 13 screws on each side. I got no less that 1/4 turn out of every screw and as much as an entire full turn out of some and, all but one tightened down. I had to remove one that was stripped and re-drill for a new screw.
Later, I decided to take a look at the hatch. This thing is crooked and it's been bothering me for some time as to whether or not I should mess with it. I can't stand it... The wood around it (coaming ?) is rotted in places and it's just not square...
So, I started by removing all of the trim around the opening. I grab my square and straight edge and start studying this picture. I think this procedure requires a beer. Drink beer while looking at square crooked hole. Think..... think..... measure this.... measure that.... drink... think.... measure... you get the picture, right. Finally, I decide to start with the upper left (looking aft) corner of the hatch opening. I figure that I'll start with this corner and square everything else to it. So, with straight edge in hand, I begin to mark off excess wood that will need to be removed. I grab a rasp and my surform and start to shave off said wood. Remove a little wood here... a little more there... a slight cut from the jig saw in a couple of corners, a little more shaving and whalla ! SQUARE.
I can live with it now. Time to call it a night.
I recently mentioned that I've ran across another blog where "Dave" is building his own boat by scratch. See his link on the left (Daves Boat). Dave lives in Ireland. It is cold in Ireland and even in the summers it doesn't get real hot I gather. If you read some of his blog you'll see that he doesn't have a garage or shop. Dave is building his boat outside... in his yard.
The Abbygirle
(Formerly called "The Goofy Mallard") she is a 17' power boat made of plywood. It has a small "Cuddy Cabin" large enough to sleep one person (2 cramped). It was originally built by Kauffman Boatworks of Osprey Florida in 1960. Over the years she has been repainted/restored several times. I don't have any more of her history just yet but, I hope to aquire as much as I can as I go along.Have you heard of Kauffman Boatworks ?
Please see entry on November 18, 2007... the Kauffmans have seen this blog site and contacted me with some info & pic's of Kauffman Boatworks and my boat.
If you have a roller mouse ( with the little roller between the left & right buttons ), you can "Click" this roller on any picture to activate the zoom function. Then you can "roll" the zoom "IN" or "OUT" as you prefer. However, the picture will become more and more distorted as you zoom in deeper and deeper.
I believe that pic's in the post/comments just need to be left clicked on to activate the enlarge / zoom feature.
Don't forget to "unclick" the roller to disable the zoom function.
If you find my boat's pic's interesting you can view more of my pic's @ http://vicslittleworkshop.shutterfly.com/action/
I first bought this boat (formerly named "The Goofy Mallard") in July of 2004. Some friends of mine had taken me boating and I was hooked the first time. I needed my own boat. Several months later the same guy that took me on my first boat adventure, who happened to have several boats, decided that he didn't need them all and so.... I was in. I gotta say, the price was right. $400.00 bucks for the craft without the engine. He wanted to keep the engine for another boat, but a few weeks later he came around and sold me the 115 hp Evinrude for another $400.00.
I had taken the boat for a test ride before agreeing to buy it and noted some damage to the keel, just under the bow. Someone had beached her in the rocks at some point in her past. They evidently tried to repair it too but, the repairs weren't of the quality that I would have prefered. The repair job itself was rotting away and the craft leaked.... a lot !
I originally intended to fix the damaged keel and put a new paint job on her and then just drop her into the water and do some fishing and relaxing. RIGHT.....................
That was in the summer of 2004. The boat still sits in my garage, completely gutted and stripped to bare wood inside and out in the midst of a full restoration. New steering system (no more pulleys & cables), new 25 gallon below deck fuel tank, new seating... the works.
I recently seen a fella's website where he is building homemade wooden boats and uses his website to sorta "Journalize" their construction. So... I thought to myself, why not me !
And this brings us to "MY BLOG".
Hope I don't bore you with my dribble...
Everyones comments are welcome.
Before we start let me say one thing though. I am not a boatbuilder nor did I know anything about boats or even woodworking when I started this project. I have spent the majority of my adult life (20 years) hammering across the U S of A in a tractor trailer delivering goods and commodities to people and business' just as fast as I could. I've never taken the time to slow down let alone learn how to do anything else with my life so, this is a major learning experience and I never move faster than what I am comfortable with.
P.S.
I still drive a truck for a living but, now I am home every night with my wife and I don't even leave the state. So.......... this is a whole new adventure for me.
This (above) is what she looked like at purchase. The windscreen is original. I know that the chrome bars extending around the bow were not part of the boat when it was built and neither was the luggage rack on the roof of the cabin.
I have no intention of restoring her to "Original" as when she was built. The craft is getting a complete overhaul though. I am intending to use two of the previous colors (this boat has been painted many times) when I paint her but, what those two colors are is my little secret here.
The first thing to do is inspect that damage (below) to the keel ( is that what it's called ?).
I see some rubbery putty looking stuff thats been "packed into and smeared around" what appears to be rotten wood on both sides of the keel guard (as well as the trailer ???). Someone (and I know who !) tried to make a "cheap fix" just to get her to stop leaking.
After getting her into the garage and off of the trailer I was able to spread some paint stripper on that spot and reveal that not only was there some rotten wood but, a small section of the original wooden keel guard (about 12" or so) had been cut out and a new piece of wood of inproper dimensions (not thick enough or wide enough) had been installed. I would soon find out that this new piece of wood was not only the wrong kind of wood but, was attached with lots (too many) of the wrong kind of screws and nails .
There was enough rotten wood to convince me that I needed to cut a hole in the hull and inspect the keel itself. You can see the two slots that are completely rotted out. This is where too many nails and screws (of the kind that rust) were used. These slots were about 3/8" wide, 1 and 5/8" deep and 3" long each. The keel is only 1 7/8" thick (all sides) to begin with. A couple of friends tried to tell me that it wasn't enough to worry about but, I'm pretty stubborn about some things. I want it fixed and fixed right.
NOW THERE IS A LONG WAITING PERIOD... MONTHS !
A trip to my favorite bookstore is in order here. I ordered two books;
Frame, Stem and Keel Repair by: The Wooden Boat Series and;
Wooden Boat Renovation by: Jim Trefethen.
A couple of weeks for delivery of the books, and a few MONTHS of getting up the courage to cut that section of the keel out.
My biggest concern here is that any and all repairs that I make to this craft are done RIGHT. I don't want anyone getting hurt trying to enjoy themselves on this boat.
!!!! ESPECIALLY ME !!!!
One obstical I encountered was how to find a piece of wood that would be suitable for the replacement section once I did get my courage up... you can't just walk into Lowe's and buy some things. That took a long time but, I finally ran into an old timer (thru my work) that takes down old barns and salvages the wood. He was able to get me a piece of 4" x 4" x 4' whiteoak timber that was no doubt twice as old as my boat was. And it was straight too !
While I was waiting, I went ahead and did other things like stripping as much of the paint as I could, removing the engine, seats and pedistals, carpeting, flooring and hardware.
??? Does anybody actually like stripping paint ???
I needed to see more of the keel itself so, this meant that I had to cut a bigger hole. I didn't want to remove any more hull matter than necessary and the hole had to be identical on both sides of the hull so, I used some posterboard (very thin cardboard) to make a pattern of the precise size and shape needed. I then carefully positioned that pattern on one side of the hull, lining it up with the keel on the inside edge and secured it to the hull with small tacks. After tracing out the hole on one side I flipped the pattern over and traced out the other side the same. Then I cut...very carefully, with a little help from a chisel.
After enlarging the hole in the hull I was able to see that the first section of the keel actually ends where my finger is pointing to. It is attached to the "Gripe or Knee" using two long silicone bronze screws and resorcinol. Removing the bad section of wood now only needs 1 cut as opposed to 2 cuts in the keel.
Here (above) you can see the keel has been installed using both epoxy and Stainless Steel bolts (I've since learned that SS should not be used below the waterline). The bolts are used aft and the original silicone bronze screws (Removing them was a breeze) up front attaching to the knee.
Along with the ordering of the books, I also had to buy the bandsaw, a couple other saws, a whole bunch of clamps and who knows what else I've been collecting out in my little workshop.
Tools are always considered to be an "Investment".
Here you see the hull patches. They are made of 3/8" okume plywood with 7 plies. I had purchased the wood thru Boulter Plywood
http://www.boulterplywood.com .
The wood was shipped directly to my house here in central Illinois.
Each patch board was carefully shaped, dry fitted and clamped into place many times untill I was satisfied that the shape was precise. This was a real pain because at the time I hadn't figured out how to flip the boat over yet. The first half (patch) took an entire day. Then I pre-drilled each piece every 2" around the outer edges all the way around. I counter-sunk the outside holes to accomidate brass screws while the inside holes (directly over the keel) would recive silicon bronze ring-shank nails. Don't ask me why I used brass :( I don't know why I used these instead of silicon bronze like I should have. Brass, I have found out is very soft. Everything else on the boat is getting silicon bronze below the waterline and bronze or SS above.
During the intire process of making each of the gussets and patchs I was lucky to have only wasted one small board due to a mistake. After making the first gusset, I got the brilliant idea that the peice on the opposite side would be identical ( a mirror image) to the first. Oooooooooops ! It doesn't work this way.
This is the end of this page. To follow the progress of my boats repairs and restoration please see the posts / comments at the top of this page and / or the archives.