Tuesday, January 17, 2017

Scarlet the Fairhaven Flyer

Two-seated Devlin Design Row Boat

One September evening we were returning from English camp to our boat Windsong in Westcott Bay by dingy.  We sighted a familiar boat from Anacortes anchored in the bay.
Walt Gutterbock and his wife, Susan were returning from their summer sailing in parts north and making their way back to home port. We stopped by for a friendly chat. Walt and Susan mentioned that they would be interested in some day having Emerald Marine build a row boat for the two of them. It was agreed that the conversation would continue later, in Anacortes. Within a year, Devlin Designing's, Fairhaven Flyer 20 was chosen.

Greg McCroskey began construction in February 2016 using 'stitch and glue' method, in which thin plywood panels are joined, cut to shape, "stitched" together with bailing wire and epoxied bonded using fiberglass cloth and taped fillets.  Those familiar with this construction method know it can be both strong, durable and lightweight. The Fairhaven Flyer is 20' 3 3/4 " in length x 4' 1 3/4" at the beam.

The last temporary stitching pulls the two hull sides together to form the bow.

Sheets 6mm plywood are scarfed 
 to create the lengths for this 20 foot hull. 
The stitching is complete and the shape has been formed.

Transom view

Frames where the seats will be constructed.

This shows the stitching where the hull sides meet the bottom of the boat at the bow. The wires will be removed as epoxy and fiberglass are applied.
Here the stern and transom seams are filleted and covered in fiberglass cloth and epoxy. An epoxy and wood dust mixture is smoothed into the seams.  The fillet further strengthens the fiberglass tape and glue connection.

The outside of the hull sanded epoxy and fiberglass, the interior and deck plywood has been sealed with epoxy alone.  Good marine "paint" will protect the surfaces further.

Greg prepares to install the aft deck
Seam fillets are sanded smooth

Rub rail  glued, screwed and plugged.  Blocks are installed for the inwales.
Decking, thwart seats and flotation boxes all provide further stability besides the obvious functions.

Nearly ready to be sent to the painters.

The inwhale is dry-fit.  It will be taken off and varnished. Then a final fastening will come after paint is applied.
Fresh back from the painter's.  Ready for hatch covers, inwhales, hardware and  oarlocks
Initial launch day for a sea trial.

Walt and Susan rowing in unison.  Sliding seats maybe installed at a later date.  

Friday, January 22, 2016

A Bird's Mouth Mast for the Spidsgatter Smil

By Kristin Stewart

If you are unfamiliar with the construction of a bird's mouth mast you may wonder how these pieces of spruce...

become this this.

Although I had seen a cross section of such a mast, I had never seen the construction from start to finish.  The completed mast for the Danish Spidsgatter Smil would be 40 feet tall with a taper from 5" at the base to  2"at the head of the mast.

James did the math to determine the taper of the staves from the top of the mast to the base. 

Measurement and calculations of stations and tapers to shape the staves

The stations on the strongback are covered in plastic so that the glued staves do not stick
This is the top end of the mast, the circumference will be planed down to a 2" radius.

This is the first dry fit using hose clamps assuring tight connections.

Shawn is putting protective plastic down on staves #5 and 8#. So that when #1-4 are glued together they only stick together forming one half of the whole mast.

The staves are glued together with a paste of epoxy and wood flour.
The stave on the top of the picture shows a scarf joint.
16-18' boards were joined to make them 40' in total

James walks to the end to turn glued stave #3 to abutt with #2.

Hose clamps are added to the smaller end first

As Shawn tightens the clamps down the line James watches for extra epoxy to squeeze between the staves.

the second half is glued up and curing

Andy planing an octagonal brace

The two halves lay side by side.  They are ready for wires, bracing and the addition of the mast step piece.

The octagonal brace is fit for structure at the position of the spreaders.

The octagonal piece is transformed into a crown brace on the bandsaw
A crown brace distributes the stress load.

Mast light wires are strung through the inside before the final glue up of the two sides.

The white tub protected the wires from being glued together.  After the glue was cured the wires were pulled out the side of the mast, through a hole, about a foot up from the bottom.

Piles of shavings from the initial rounding of the mast.  Next, concave pieces of  styrofoam and sand paper
were used to sand it even and round.

Purpleheart wood 'hounds'  where the mast bands set for rigging and sail track mounts

The mast gets its top coats of varnish.

Tuesday, December 29, 2015

Joshua's fresh new transom

A mild fall and winter last year made for decent outdoor work from October 2014 to the end of January 2015.  We had frequent visits from Bill who was active in the work and encouraged progress.  I personally enjoyed Bill's visits to the office, marked with humor, stories, and musings.  Andy, I and the shop built a friendship upon an acquaintance for which we are richer.  In late summer, we had the pleasure of visiting with Bill, Mary Alice and their crew/friend Dick, aboard Joshua in Doe Bay, Watmaugh Bay and then in Port Townsend for the Wooden Boat Festival, as they concluded their annual cruise in the inside passage.

Andy has captioned the pictures below with descriptions of the work.

Joshua at anchor in Watmaugh Bay

Our friend Bill's Spray replica, Joshua.  She'd been leaking from the deck

Some frame parts (futtocks) and the ends of the shelves and clamps were rotten.

Futtocks dry fit, working on the transom frame
New layers  (lift) in the taffrail, shelf/clamp assembly being re-engineered across the stern
Puzzling out the configuration of the quarter knees, clamps, shelves and transom frame

Locust quarter knees made and dry fit, ready for paint

Aft deck shelf and clamp

Shelf/clamp/ quarter knees installed, fitting covering board from below. Sprung into place.

Fitting top of transom frame under covering board. Also new frames down the sides

Bolting the frame heads to the structure

Lots of shape in the quarters

Framing and covering board all completed ready for planking

James working out the covering board on this side. He built it in two pieces to get around the frame heads and bulwarks
Planking begins, some ends were scarfed on.  Bill is having fun, as usual.  It's fir across the stern and yellow cedar on the sides. All galvanized fasteners.

Cork'er up and she'll float!

A boat on wheels?

And a good day to you sir!