Sketch of the Process

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Sketch of the Process Safety

A Sketch of the Process

The first step is to set up your shop. If you are like me, that includes cleaning it. I recommend ripping the strips, gunwales and keel before building the mold, because unless you have a lot of room, once the mold is assembled, there is not going to much room for handling long boards. After ripping and edgin the long pieces, the strongback is assembled. Then the forms are cut out and mounted on the strongback. The result is called the mold. The strips are then glued together on the mold (but not to the mold) to create the hull. While the completed hull is still on the forms, the outside is sanded smooth and fiberglass is applied with sufficient epoxy to fill the fiberglass weave. The hull is then removed from the mold, righted, and placed in cradles mounted on the strongback. The inside of the hull is then made smooth. Once that is done, its all downhill. Apply fiberglass to the inside, but this time there are no fill coats. The hull is now finished. The final steps are to install the gunwales, decks, seats, and yoke or thwart. Before you head to deep water, apply two or three coats of clear marine finish and you are ready to go.

Ripping the Strips, Gunwales, and Keels

Select wood species based on preferences, cost, and availability Size the boards to desired strip width while paying attention to the grain orientation Rip the strips Store the strips While you have the table saw set up, go ahead and rip the pieces for the gunwales and keels

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Sketch of the Process

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Milling the Strips, Gunwales, and Keels

Locate some canoe bits for your router Set up your router in a table with plenty of feather boards and long infeed / outfeed surfaces Run some test strips Route the bead and then the cove Store the strips While you have the router table set up, go ahead and mill the gunwales and keels

The Mold
Layout the forms on poster board Transfer the form patterns to the form material (typically 1/2" plywood) Cut out the forms and drill the batton holes Assemble the strongback stands Assemble the strongback Mount the forms on the strongback Assemble the cradles for later use

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12.11.2010

Sketch of the Process

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12.11.2010

Sketch of the Process

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Stripping the Hull

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Sketch of the Process

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Fiberglassing the Hull Trim Making and Hanging the Seats Applying the Finish

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12.11.2010