DESIGNER

Michael Storer
Adelaide, Australia
Email storerm@ozemail.com.au
Mob 04! "4# 4$$
%able o& 'o(te(ts
Table of Contents...................................................................................................................2
LICENCE................................................................................................................................3
PADDLES Overview...........................................................................................................3
Comments on Paddles......................................................................................................3
TI!E"..................................................................................................................................#
Timber Sele$tion................................................................................................................#
Pl%wood.............................................................................................................................#
TI!E" LIST.........................................................................................................................#
EPO&' ST()).....................................................................................................................*
ISCELLANEO(S ATE"IALS...........................................................................................*
TOOLS...................................................................................................................................+
A,IN- PADDLES................................................................................................................
a/in0 t1e Paddle to )it 'o2rself.......................................................................................
S1a3in0 t1e S1aft..............................................................................................................4
Laminatin0 a s1aft ............................................................................................................4
PADDLE S5A)T DIENSION D"A6IN-............................................................................7
ar/in0 t1e S1aft.............................................................................................................89
Planin0 t1e first two fa$es................................................................................................88
"o2ndin0 t1e S1aft ma/in0 and 2sin0 a s3ar 0a20e................................................... 88
Planin0 t1e se$ond two fa$es..........................................................................................82
ar/in0 t1e 3addle blade s$oo3s....................................................................................82
C2ttin0 t1e s$oo3s...........................................................................................................82
a/in0 t1e blan/ 4 sided.................................................................................................82
C2t t1e 3l% for t1e blades.................................................................................................83
-l2in0 t1e blades on t1e s1aft t1e dr% r2n NO -L(E 'ET.......................................8#
-l2in0 t1e blades on t1e s1aft t1e real t1in0:::.............................................................8#
)ittin0 t1e 1andles to t1e sin0le blade 3addle.................................................................8#
S1a3in0 t1e 1andles........................................................................................................8*
"o2ndin0 t1e S1aft and 1andle.......................................................................................8*
5and sand to 0et rid of sandin0 mar/s from ro2ndin0 t1e s1aft..................................... 8*
)inal E3o;% $oatin0.........................................................................................................8+
Paintin0 and <arnis1in0...................................................................................................8+
APPENDICES......................................................................................................................8.
Cordless !atter% Drill wit1 Cl2t$1....................................................................................8.
6et=on=6et Coatin0 and Dewa;in0 C2red E3o;%..........................................................8.
)illetin0 and -l2in0 2sin0 >Sna3 Lo$/? Plasti$ !a0s.......................................................8.
-ivin0 'o2rself Time.......................................................................................................84
!2ildin0 stron0 li01twei01t boats and items = a note on t1e 2se of e3o;%...................... 84
@ i$1ael Storer 2
)I'EN'E
T1e download of t1is 3lan entitles t1e 32r$1aser to b2ild 3addles for t1eir own boatAs.
T1e ri01t to ma/e 3addles to t1ese 3lans for sale to ot1ers is b% a f2rt1er small fee 3er
3addle to be ne0otiated wit1 t1e desi0ner. Conta$t storermBoCemail.$om.a2
T1e 32r$1aser m2st de$ide w1et1er t1e 3addle will s2it t1eir 32r3oses. I 1ave offered a
des$ri3tion of t1e 3addle and its b2ildin0 w1i$1 is offered in 0ood fait1D b2t it is limited in
t1at it is m% o3inion onl%. As t1ere is no $ontrol over t1e materials or wor/mans1i3 t1ere is
no warrant% e;3ressed or im3lied.
*ADD)ES +,er,ie-
Comments on Paddles
T1ere are two 3addles detailed in t1is 3a$/ sin0le bladed and do2ble bladed.
It is 2s2al to $arr% sin0le bladed 3addles on a $anoeD b2t a do2ble bladed 3addle $an be
2sef2l as an a2;iliar% w1en 3addlin0 b% %o2rself or in $alm $onditions. T1ere is
information on siCin0 t1e 3addles to t1e 2ser = t1is is 3arti$2larl% im3ortant on lon0 tri3s.
,a%a/s and one 3erson $anoes 2s2all% 2se a do2ble bladed 3addle.
an% man2fa$t2red 3addles are desi0ned to s2it t1e stren0t1 of a $om3etitive 3addler
w1o trains re02larl%. As a res2lt t1e blades are too lar0e and t1e re$reational or distan$e
3addler will tire E2i$/l% and 1ave diffi$2lt% 1andlin0 t1e 3addle in waves and wind.
T1e 3addles in t1is 3lan 1ave been desi0ned aro2nd re$reational 2se and a wide ran0e of
weat1er and sea $onditions. T1e% are 0eneral 32r3oseD desi0ned for $overin0 distan$eD
not for s3rints or ti01t mane2verin0 a0ainst t1e $lo$/. A s3e$ialist 3addle will be better in
t1ose $ases.
T1e $onstr2$tion is solid timber for t1e s1aft and two la%ers of 3mm 3l% for t1e blade. T1is
form of blade $onstr2$tion is far stron0er and li01ter t1an s1a3in0 t1em from solid timber
so it e;3e$ted t1at t1e 3addles will stand 23 to ri0oro2s 2se. T1e $onstr2$tion also allows
t1e 3addles to be E2i$/l% $onstr2$ted.
T1e 3lans are in metri$ meas2re. T1is is b% far t1e most $onvenient and 2niversal s%stem.
Some of m% more 3o32lar boat 3lans 1ave materials lists in bot1 s%stems to sim3lif%
orderin0D 1owever t1e b2ildin0 instr2$tions are alwa%s in metri$.
@ i$1ael Storer 3
%IM.ER
Timber Sele$tion
It is best to ma/e 3addle s1afts from strai01tD /iln dried fine 0rain timber.
T1e most a33ro3riate timber to $1oose in A2stralia is Ore0on FDo20las )irG. ost of t1e
s3r2$e F2s2all% E2oted in as t1e a33ro3riate timberG t1at we see in t1is $o2ntr% is 3oor
0rade and war3s badl% w1en $2t or over time. S3r2$e t1at is fine 0rain and dried 3ro3erl%
will not war3 b2t is e;3ensive and 1ard to 0et.
Paddle s1afts need to be li01t b2t stron0. )ine 0rain 0ives stren0t1 and resilien$e. To see
if t1e 0rain is fine eno201D loo/ at t1e ann2al rin0s on t1e end of t1e 3ie$e. T1ere s1o2ld
be 2* 0rains 3er in$1.
T1e timber s1o2ld be /not free.
6ar3ed timber is 1eartbrea/in0 in 3addlesD 1owever a small amo2nt of war3in0 $an be
eliminated in t1e s1a3in0 3ro$ess.
Timber wei01ts var% E2ite a bit. It is more im3ortant to 1ave t1e timber fine 0rained and
/not freeD b2t if %o2 1ave to $1oose between two 3ie$es ta/e t1e less 1eav%.
Pl%wood
T1e 3l%wood for t1e blades s1o2ld be 3mm t1i$/. -aboon marine 3l% wo2ld be
re$ommended for its li01t wei01t. Conta$t me if %o2 1ave diffi$2lt% findin0 a s233lier in t1e
siCes t1at %o2 need
%IM.ER )IS%
all dimensions are finis1ed siCes and are in mm 2nless stated ot1erwise.

Ore0on = Do20las )irD S3r2$eD sele$t dr% sto$/. )ine 0rainD no /nots. See notes above.
Part SiCe Len0t1 N2mber S3e$ies
3mm -aboon Pl% 33l%
Sin0le Paddle *49 H 23* = 2
Do2ble Paddle *2* H 849 = #
S1aft
Sin0le Paddle 32 H 32 8*99 8 Ore0on
Do2ble Paddle 32 H 32 2*99 8 Ore0on
5andle
Sin0le Paddle 32 H 3+ 2*9 8 Ore0on
Do2ble Paddle none
@ i$1ael Storer #
E*+/0 S%122
E3o;% 8.* litres will do two sin0le 3addles and a do2ble
)ortifier 0l2in0 3owder 9.* /0 or less
MIS'E))ANE+1S MA%ERIA)S
!arrier $reme for 1ands If %o2 2se it reli0io2sl% t1e e3o;% will $ome off wit1 soa3
and water. DO NOT (SE SOL<ENTS )O" CLEANIN-
S,IN.
!a0 of dis3osable 0loves
)oam rollers 8 = t1e% 1ave a t1in la%er of foam on t1e $ard board
roller. If %o2 $an 0et a s1ort roller $a0e 1andle Fas/ %o2r
e3o;% s233lier or in$l2ded in /itG it means t1e rollers $an
be $2t in t1ree = a 0ood e$onom% for a little boat li/e t1is.
as/in0 ta3e 87mm F3A#IG wide
"oll of 3lasti$ 3a$/a0in0 ta3e 3.mm or *9mm wide F8 8A2 or 2IG.
S1eets sand3a3er = al2mina 3a3er Fw1ite 0ritG is best.
# s1eets ea$1 of 899 0rit and 849 0rit
Some 3lasti$ s1eetin0 wo2ld be 2sef2l.
5ea3s of $leanD em3t% tin $ans
Stirrin0 sti$/s made of s$ra3 timber 299 b% 29 b% +mm a33ro;.
@ i$1ael Storer *
%++)S
Ta3e eas2re = T1e best t%3e for boatb2ildin0 1as etri$ on one side and in$1es wit1
si;teent1s mar/ed on ot1er.
etal strai01t ed0e aro2nd a metre F3 = #ftG lon0.
Combination sE2are.
Ji0saw andAor Ja3anese ba$/ saw. Tenon saw wo2ld wor/ o/a%.
Planes = small blo$/ 3lane or Stanle% K# or similar.
S3o/es1ave
C1isel = 87mm or 2*mm F3A#I and 8IG
S1ar3enin0 Stone = to /ee3 t1e Planes and C1isels s1ar3.
5onin0 oil = to 2se on stone. 'o2 $an ma/e %o2r own b% addin0 a small amo2nt of en0ine
oil to ,erosene FParaffinG = a $o23le of tables3oons to a 3int.
)iles = a ras3 and wit1 ro2nd ba$/.
Sandin0 !lo$/
Clam3s = $lam3s $am be e;3ensive. I 2s2all% 0et awa% wit1 a $o23le of reasonable
E2alit% -=$ram3s or slidin0 bar $lam3s wit1 a minim2m o3enin0 of 899mm F#IG.
O$$asionall% it is 3ossible to find $1ea3 slidin0 bar $lam3s from Taiwan for aro2nd L3D
w1i$1 I $olle$t w1en I $an. T1e most use&ul and $1ea3 $lam3s are Is3rin0 $lam3s
Fsometimes $alled welders $lam3sG t1e% sell for aro2nd L2 * to 89 wo2ld be 2sef2l for
t1is and man% ot1er 3roMe$ts. a/e s2re t1e% 1ave a stron0 s3rin0in0 a$tion.
@ i$1ael Storer +
MA3ING *ADD)ES
a/in0 t1e Paddle to )it 'o2rself
Si(4le *addle = Sit wit1 a 0ood 3ost2re on a 1ard $1air or
ben$1. eas2re t1e distan$e from t1e ti3 of %o2r nose to
t1e ben$1 in millimetres. T1is is $alled %o2r Ibase
meas2rementI.
Add .*mm to t1e base meas2rement if %o2 are s1ort or
avera0e 1ei01tD and 899mm if %o2 are tall. Now add
#4+mm to 0ive t1e len0t1 of timber reE2ired for t1e s1aft.
% base meas2rement is .*9mmD m% 3addleNs s1aft is
.*9O.*O#4+P8388mm. T1e blade will e;tend abo2t
.2mm 3ast t1is meas2rement.
T1ere is a basi$ widt1 for t1e sin0le blade 3addle blade. It $an be de$reased b% a total of
29mm for $1ildren or wea/er 3addlers or in$reased b% a similar amo2nt for ver% stron0
3addlers Fif t1e blade is too lar0e it is 3ossible to red2$e t1e widt1 after tr%in0 it o2t.
Double *addle = T1e overall len0t1 of t1e do2ble 3addle is 2#.*mm. T1is will be
a33ro3riate for all b2t ver% narrow boats. If %o2r boat is ver% narrow Fless t1an +3*mmG
%o2 $an ded2$t 8*9mm from t1e 3addle len0t1. T1e ta3ered 3art at ea$1 end of t1e loom
will 1ave to be s1ortened b% .*mm ea$1 side.
)eat1erin0 3addles w1ere t1e blades are at ri01t an0les are most effi$ient and are s1own
in t1ese drawin0s. Some Sea ,a%a/ers doin0 offs1ore wor/ $1oose 2nfeat1ered 3addles
as stron0 wind $an 0et 2nder t1e blade and ti3 t1e /a%a/ over.
6or/ o2t w1et1er %o2 want a ri01t or left $ontrol 3addle = see dia0ram o33osite. ar/ t1e
s1aft so t1e 3osition of t1e blades are $lear.
T1e 3addle wit1 ri01t 1and $ontrol is m2$1 more $ommon. T1e ri01t 1and twists sli01tl% at
t1e wrist to 3resent ea$1 blade in t2rn to t1e water. T1e s1aft is allowed to rotate freel% in
t1e left 1and.
T1ere is more strain on t1e wrist of t1e $ontrol 1and. As I 1ave a sli01t 3roblem in m% left
wrist I 2se a ri01t $ontrol 3addle.
If in do2bt ma/e t1e 3addle ri01t $ontrol.
@ i$1ael Storer .
S1a3in0 t1e S1aft
T1e 3addles in t1ese 3lans are desi0ned to be as sim3le to b2ild as 3ossibleD so s3e$if% a
s1aft made of one 3ie$e of timber. It is 3ossible to laminate t1e s1aftD b2t if t1e timber is
$1osen $aref2ll% it is not ne$essar%.
"easons for laminatin0 t1e s1afts $an var% from 2sin0 $ontrastin0 timbers for a33earan$eD
ma/in0 a sin0le 3addle wit1 a bent s1aftD or if s2itable timber for a one 3ie$e s1aft is
2navailable or war3ed. 3 or . de0rees is E2ite $ommon for bent s1aftsD t1o201 t1e% $an
0et 23 to 8# de0rees or more. T1e bendin0 ma/es t1em more effi$ient in a strai01t lineD
b2t less s2itable for mane2verin0 in and w1en 2sin0 fan$% stro/es.
A dimensioned s1aft drawin0 is on t1e ne;t 3a0e
Laminatin0 a s1aft
5s6i7 this sectio( i& usi(4 o(e 7iece o& timber &or the sha&t8
T1e followin0 des$ri3tion is for t1ose w1o wis1 b2ild a laminated s1aft.
T1e s1aft will 1ave to be laminated o2t of at least fo2r la%ers of timber. If %o2 are 3lannin0
to ma/e a 3addle wit1 a ver% bent s1aftD si; la%ers ma% be more a33ro3riate.
Leave t1e timber over len0t1 for t1e moment.
6or/ o2t 1ow %o2 are 0oin0 to $lam3 t1e timber after 0l2in0. Do a dr% r2n if in do2bt.
La% o2t t1e timber in t1e order of t1e laminations.
i; 23 eno201 resin and 3re$oat wit1 a t1in la%er on 0l2in0 s2rfa$es. Add 0l2in0 3owder
to e3o;% to ma/e a I1one% li/eI $onsisten$%D s3read on one of ea$1 3air of adMa$ent fa$es
and $lam3 to0et1er. Alternate t1e $lam3 1andles to fa$e in alternatin0 dire$tions so t1e
wei01t wonNt twist t1e blan/.
To ens2re t1e blan/ 0l2es 23 strai01t 32t it on its side so t1e 0l2e Moint is verti$al = si01t
alon0 t1e Moin to ens2re it is r2nnin0 strai01t F2nless it is a bent 3addle:G If it isnNt %o2 ma%
1ave to loosen some of t1e $lam3s to adM2st.
61en t1e 0l2e is dr% remove t1e $lam3s and 2se a belt or dis/ sander to remove an% 0l2e
@ i$1ael Storer 4
r2ns. !e $aref2l not to lose t1e sE2are s1a3e of t1e s1aft.
*ADD)E S9A2% DIMENSI+N DRA:ING
@ i$1ael Storer 7
ar/in0 t1e S1aft
T1e ta3er is mar/ed on two o33osite sides of t1e timber s1aft. T1e ot1er two fa$es are
3laned down to t1ose ta3ers. )ollow t1e met1od below
ar/ and $2t t1e s1aft blan/ to len0t1.
T1e s1aft dimensions are 0iven at different 1ei01ts in t1e S1aft Drawin0. FIf attem3tin0 to
eliminate some war3a0e in t1e materialD 32t t1e intervals for t1e most ta3ered end of t1e
s1aft toward t1e most war3ed endG.
(se t1e $ombination sE2are to mar/ t1e intervals a$ross t1e fa$e of t1e blan/.
(se t1e sE2are to transfer t1e interval lines onto t1e ot1er t1ree fa$es.
T1e front and ba$/ fa$es of t1e s1aft 1ave to mar/ed wit1 t1e ta3er as a 02ide for 3lanin0
down t1e sides. T1e 3addle blade 3ositions mar/ed earlier will 0ive identif% t1e front of t1e
s1aft. )eat1erin0 do2ble bladed 3addles will 1ave t1eir ends ta3ered at 79 de0rees to one
anot1er.
6or/ alon0 t1e s1aft meas2rin0 and mar/in0 t1e $orre$t widt1 on ea$1 interval. FNote = if
attem3tin0 to eliminate a war3 t1e 3addles will 1ave to be mar/ed wit1 a strai01t $entreline
2sin0 a tensioned strin0 or strai01ted0e.G
T1e obMe$t is to ta/e an eE2al amo2nt off ea$1 side = so if t1e blan/ fa$e is *9mm wide
and t1e reE2ired widt1 is #+mmD t1en 32t a mar/ 2mm in from ea$1 side. 'o2 will also
need to mar/ t1e o33osite fa$e wit1 t1e same meas2rement.
61ere fra$tions of a mm are 0iven estimate t1e 3osition t1at t1e mar/ needs to be. A
s1ar3 3en$il is essential.
See t1e dia0ram above to see 1ow t1ere is a s2dden $1an0e in s1a3e at t1e s1aft ne$/D
w1ere t1e blade will atta$1. T1e elli3ses s1ow t1e $ross se$tion $1an0es at different
1ei01ts $ir$2lar at t1e left 1and side alterin0 to an elli3se.
@ i$1ael Storer 89
Planin0 t1e first two fa$es
Pla$e t1e blan/ at an a33ro3riate 1ei01t for 3lanin0. T1e mar/ed fa$es s1o2ld be to t1e
sides Clam3 it down 2sin0 a s$ra3 of timber 2nder t1e $lam3 so t1e timber is not $r2s1ed.
,ee3 t1e $lam3 awa% from t1e area t1at %o2 are 0oin0 to be wor/in0. 6or/ on one end of
t1e ta3er at a time.
(se t1e lon0est 3lane 3ossible AND ,EEP IT S5A"P. If it 0ets bl2nt it will start to s3lit t1e
timber. -l2e Moins will bl2nt t1e 3lane E2i$/l%.
A s3o/es1ave ma% be ne$essar% for s1a3in0 t1e $1an0e of ta3er at t1e ne$/.
Start 3lanin0 from t1e areas w1ere most wood 1as to be removed = if t1e 0rain starts liftin0
tr% 3lanin0 in t1e o33osite dire$tion.
Contin2e 3lanin0D $1e$/ to ma/e s2re t1at %o2 are a33roa$1in0 t1e ta3er mar/s on bot1
sides evenl%. DO NOT PLANE T5E O)).
To 3rod2$e a smoot1 ta3er (SE LON- ST"O,ES O) T5E PLANE Ft1o201 stro/es will
1ave to sto3 at t1e ne$/G. Tr% and remove t1e timber evenl% = donNt $on$entrate on one
s3ot or %o2 will end 23 wit1 a 1ollow. As %o2 0et $loser adM2st t1e 3lane for finer and finer
$2ts. 61en t1e first end is done ta3er t1e ot1er.
"o2ndin0 t1e S1aft ma/in0 and 2sin0 a s3ar 0a20e
T1e s1aft is now ta3ered b2t sE2are. A s3ar 0a20e is 2sed to mar/ for 3lanin0 off t1e
$orners to ma/e it ei01t sided. See fi02re below
Loo/ at t1e S3ar 0a20e Drawin0. T1e s3ar 0a20e for Q#9mm is best for 3addle ma/in0. If
%o2 1ave ot1er sli01tl% lar0er s1afts to do %o2 ma% wis1 to s$ale it 23 to do all t1e siCes
%o2 need. Fnote = a s3ar 0a20e 0ets less a$$2rate if it is made too far oversiCe = donNt
s$ale 23 more t1an *9R over t1e 0iven siCe.
T1ere is an o3tion to 2se eit1er 3en$ils or s1ar3ened nails to mar/ t1e lines. I 3refer t1e
nails as %o2 $an still see t1e lines if %o2 1a33en to 3lane a little too far. Pen$ils wor/ fine if
s1ar3.
@ i$1ael Storer 88
61en t1e 0a20e is madeD 3la$e it over t1e blan/ at one end. Twist it so t1at t1e 02ides sit
flat on eit1er side of t1e blan/.
P2ll t1e 0a20e toward %o2 ma/in0 s2re t1at t1e 02ides are /e3t flat on t1e timber. T1ere
s1o2ld be two $lear lines bein0 mar/ed on t1e timber. If not %o2 ma% 1ave to adM2st t1e
nailsA3en$ils.
As %o2 3ro$eed toward less ta3ered areas t1e 0a20e will move to a less and less a$2te
an0le adM2stin0 t1e 3osition of t1e two lines a2tomati$all%.
Planin0 t1e se$ond two fa$es
T1e ta3ers are mar/ed for t1e two remainin0 fa$es and t1en t1e% are 3laned down
remember t1at t1e s1aft will 1ave different ta3ers or be 2nta3ered for t1e se$ond two
fa$es. C1e$/ t1e drawin0s $aref2ll%.
ar/in0 t1e 3addle blade s$oo3s
Now t1e ta3er is $2t t1e s$oo3 for t1e
blades $an be mar/ed.
T1ere are two S$oo3 Tem3lates = one
ea$1 for t1e sin0le 3addle and t1e do2ble
3addle. Ta3e t1e tem3late down to stiff
$ardboard or 3l%wood and $2t $aref2ll%
aro2nd t1e o2tline. (se s$ra3 3l%wood or
timber if %o2 are 0oin0 to ma/e more t1an
one 3addle to ma/e a more 3ermanent
tem3late.
ar/ t1e tem3late so %o2 /now w1i$1 end is t1e to3 of t1e blade.
ar/ t1e s$oo3 on t1e sides of t1e loom. T1e tem3late is 3ositioned as s1own above If
%o2 want to ma/e several 3addles it ma% be wort1 ta3in0 t1e tem3late to some s$ra3 3l%
and $2ttin0 it o2t wit1 a Mi0saw to ma/e a 3ermanent tem3late
C2ttin0 t1e s$oo3s
(se a Mi0saw or band saw to $2t t1e
s$oo3s on t1e s1afts. 6or/ $aref2ll% and
$1e$/ t1at t1e blade is followin0 t1e
$orre$t 3at1 on !OT5 sides of t1e loom =
it ma% tend to wander.
(se t1e s3o/es1ave to 3lane t1e s$oo3s
down to t1e line.
a/in0 t1e blan/ 4 sided
61en t1e lines are mar/ed on all fa$esD 3lane off t1e $orners of t1e blan/.
@ i$1ael Storer 82
Caref2ll% 3lane down to t1e lines left b% t1e s3ar 0a20e.
LEA<E T5E !LAN, "ECTAN-(LA" )"O T5E NEC, DO6N AND IN T5E 5ANDLE
A"EA Fsin0le 3addles o33osite end of t1e s1aft from t1e blade s$oo3G = IT 6ILL !E
S5APED A)TE" T5E !LADES A"E LAINATED IN PLACE.
T1e s1aft needs to be t1inned as in t1e dia0ram o33osite. Note t1e ta3er is different for
sin0le and do2ble bladed 3addles. ,ee3 t1e $2rve smoot1 as %o2 3lane it down.
Hdia0ram see 3rev 3ara H
61en satisfied wit1 t1e ta3er 2se t1e blo$/ 3lane to $ontin2e t1e ei01t sidin0 down to t1e
end of t1e s1aft b% e%e. !e $aref2l not to 0o20e t1e blade wit1 t1e $orner of t1e 3lane.
a/in0 t1e blan/ 8+ sided and ro2ndin0
In smaller s1afts and s3ars F23 to .*mm diameterG t1e $orners are 3laned off b% e%e to
3rod2$e8+ sides. T1is is t1e $ase wit1 3addle s1afts t1e met1od follows.
)or s1afts t1is siCe it will be im3ossible to set 23 t1e 0a20e for 8+ sidin0 = t1e two inner
1oles will be too $lose to0et1er. In t1is $ase it will 1ave to be done b% e%e.
(se w1ite $1al/ to mar/ bands aro2nd t1e s1aft abo2t *9 to .9mm a3art. T1is will allow
%o2 to see w1ere %o2 1ave 3laned.
Plane met1odi$all% finis1in0 one $orner before movin0 on to t1e ne;t = or %o2 will lose
tra$/ of w1ere %o2 1ave been. at$1 t1e siCes of t1e 3laned fa$es to t1e 2n3laned fa$es
b% e%e.
8+ side t1e 1andle and s1aft at t1e 3addle end as well 2sin0 t1e s3o/es1ave.
C2t t1e 3l% for t1e blades
@ i$1ael Storer 83
(se t1e s233lied !lade Tem3lates to mar/ t1e s1a3es on 3mm 3l%. T1ere are two 3ie$es
FlaminationsG needed 3er blade.
C2t and sand one lamination 3er blade a$$2ratel% to s1a3e. T1e ot1er $an be $2t *mm
oversiCe for t1e moment.
Clam3 t1e a$$2rate s1a3e in 3la$e. AdM2st 2ntil it is 3erfe$tl% sE2are. ar/ t1e 3osition b%
mar/in0 t1e loom s1a3e on t1e blade b% r2nnin0 a 3en$il aro2nd it. If t1ere are l2m3s and
b2m3s sto33in0 t1e 3l% from mat$1in0 t1e s$oo3 s1a3e neatl% remove t1em wit1 t1e
s3o/es1ave.
-l2in0 t1e blades on t1e s1aft t1e dr% r2n NO -L(E 'ET.
61en a $lam3in0 3ro$ed2re is a little $om3li$ated I alwa%s do a dr% r2n $lam3
ever%t1in0 to0et1er wit1o2t t1e 0l2e. T1is ma/es s2re %o2 1ave %o2r met1od ri01tD rat1er
t1an findin0 %o2 donNt and 1ave t1e 0l2e ra3idl% 1ardenin0 or M2st $reatin0 a bi0 mess as
%o2 tr% to 0et ever%t1in0 ri01t.
Do a dr% r2n to ma/e s2re t1at bot1 laminations $an be $lam3ed in 3osition wit1 t1e
available $lam3s. Clam3 t1e two blade laminations to0et1er wit1 two $lam3s on ed0esD
t1en bend t1e laminations in 3la$e on t1e s1aft b% $lam3in0 t1em in 3la$e. P2t additional
s3rin0 $lam3s aro2nd t1e 3erimeter of t1e blades to 1old t1e two blade laminations
to0et1er. T1ere s1o2ld be minimal 0a3s wit1o2t e;$essive $lam3 3ress2re.
"emove $lam3s.
-l2in0 t1e blades on t1e s1aft t1e real t1in0:::
!r2s1 resinA1ardener mi; onto t1e s$oo3 area of t1e s1aft. T1is is ne$essar% be$a2se t1e
obliE2e ends of t1e s$oo3s 1ave e;3osed end 0rain. End 0rain is 1i01l% absorbent and
ma% s2$/ all t1e e3o;% awa% from t1e Moint area.
Add t1e 1i01 stren0t1 0l2in0 3owder to t1e tin of e3o;%.
A33l% e3o;%A3owder mi; to t1e matin0 s2rfa$e of t1e
3addle blades and t1e s$oo3 area of t1e s1aft and
re$lam3 in t1e $orre$t 3osition.
6ait 1alf an 1o2r t1en tid% 23 an% 0l2e ooCin0 o2t
from t1e Moins.
)ittin0 t1e 1andles to t1e sin0le blade 3addle
C2t t1e 1andle trian0les as s1own and mar/ t1eir
3osition on t1e s1aft.
6or/ o2t 1ow to $lam3 t1e 1andle trian0les in 3la$e
on t1e s1aft. It $an be 2sef2l to ta3 a fine nail Fm2st
be fine or t1e 1ole will s1ow w1en t1e 3addle is
finis1edG 3artiall% into t1e s1aft to sto3 t1e trian0les
from sli33in0. in 3la$e so t1at
@ i$1ael Storer 8#
A33l% 0l2e to t1e 1andle trian0les and $lam3 ba$/ in 3la$e.
S1a3in0 t1e 1andles
(se a 3ower sanderD ras3 or $oarse sand3a3er on a blo$/ to sand t1e 1andle trian0le
fa$es down fl2s1 wit1 t1e s1aft.
(se t1e 5andle Tem3late to mar/ t1e finis1ed 1andle o2tline on t1e 3addle. Trim it to t1at
s1a3e 2sin0 a Mi0saw Fma/e s2re t1e saw $2t is verti$al and not $2ttin0 too far in on t1e
2ndersideG.
(se t1e s3o;es1ave to $ontin2e t1e ei01t sidin0 of t1e s1aft 23 t1e sides and a$ross t1e
to3 of t1e 1andle b% e%e. See Dia0ram o33osite.
-ras3 t1e 1andle = see if it is startin0 to feel $omfortable to 0ri3. Contin2e to ro201 o2t t1e
1andle.
"o2ndin0 t1e S1aft and 1andle
Now to ro2nd t1e s1aft.
It is best to 2se a sandin0 belt = t1ese are ver% d2rable = 0et t1em as lon0 as 3ossible = $2t
t1em near t1e man2fa$t2re Moin. Alternativel% 2se a len0t1 of sand3a3er sold off t1e roll at
5ardware stores. 'o2 will need 899 to 829 0rit $oarse belts for $oarse s1a3in0 and a 849
0rit medi2m for final ro2ndin0.
(sin0 t1e $oarse beltD wra3 it 849 de0rees aro2nd t1e s1aft. An0le t1e 3a3er so it is
aro2nd #* de0rees from t1e 3er3endi$2lar.
S1a3e t1e s1aft onl% at t1is sta0e. Sand 2ntil t1e rid0es are aro2nd 79 3er$ent 0one.
T1en move down to t1e finer 3a3er. Contin2e sandin0 2ntil t1ere is onl% sli01t eviden$e of
t1e flats.
(se t1e same met1od to s1a3e t1e 1andle.
T1e s1aft at t1e blade end $an 1ave its $orners 3laned off on$e more wit1 a <E"' finel%
set 3laneD t1en be sanded wit1 $oarse t1en fine sand3a3er on a blo$/ to 0et rid of t1e
rid0es. To 3revent 0o20in0 t1e ba$/ of t1e blade it $an be mas/ed off wit1 m2lti3le la%ers
of mas/in0 ta3e.
5and sand to 0et rid of sandin0 mar/s from ro2ndin0 t1e s1aft.
T1e final sta0e is to 0et rid of t1e sandin0 mar/s t1at are r2nnin0 1eli$all% aro2nd t1e s1aft
and 1andle. To do t1isD sand alon0 t1e 0rain wit1 1and1eld sand3a3er Fa33ro; 229 0ritG
2ntil t1e s$rat$1es are 0one.
T1e s1afts are now s1a3ed.
@ i$1ael Storer 8*
Trim t1e blades to t1eir final s1a3e and sand a sli01t radi2s on t1e $orners of t1e blade.
)inal E3o;% $oatin0
"ead t1e a33endi$es abo2t >wet on wet a33li$ation of e3o;%? and dewa;in0 e3o;% before
$ontin2in0. )ollow %o2r e3o;% man2fa$t2rerNs dire$tions
E3o;% man2fa$t2rers 2s2all% re$ommend 3 $oats over wood.
61en e3o;% 1as $2redD dewa; Fsee a33endi$es firstG and t1en varnis1 Fma/e s2re varnis1
1as (< filters = s3ar varnis1G = follow dire$tions on $an.
Almost finis1ed:
)inall% w1en all t1e e3o;% 1as $2red sand t1e s2rfa$e li01tl% to remove t1e s1ine. T1e
boat is now read% for 3aintin0 or varnis1in0.
Paintin0 and <arnis1in0
T1ere are two basi$ t%3es of 3aints and varnis1es.
!.%-o 7ot = w1i$1 is ver% 1ard and d2rableD b2t $an be 1ard to 0et a 0ood finis1 wit1 a
br2s1 and to to2$1 23. 'o2 1ave to be $aref2l of t1e f2mes. No 3rimer or 2nder$oat is
reE2ired.
;.'o(,e(tio(al ,ar(ishes = t1in wit1 t2r3sD are easier to 32t onD b2t ma% remain soft for
some time. T1e $onventional varnis1es often 1ave a better 0loss and I t1in/ t1e% are
m2$1 more 3leasant to 2se Ffeel ni$eAsmell ni$eG.
(se varnis1 and 3aints a$$ordin0 to man2fa$t2rerNs dire$tions. A 3rofessional finis1 is 79
3er$ent de3endant on 0ettin0 t1e s2rfa$e smoot1 between ea$1 $oat.
If varnis1 is $ontin2all% e;3osed to s2n it will need a li01t sand and two or t1ree new $oat
ever% %ear Fless in Nort1ern A2straliaG.
Two 3ot varnis1 will 0o for a $o23le of %ears 2nder t1e same $onditions.
,ee3in0 t1e boat and 3addles o2t of t1e s2n will red2$e need for maintenan$e man% fold.
@ i$1ael Storer 8+
A**ENDI'ES
Cordless !atter% Drill wit1 Cl2t$1.
A marria0e made in 1eaven. T1e drill $an be batter% Fmost $onvenientG or mains 3owered.
It is best if it 1as a variable $l2t$1. If %o2 1ave a drill wit1o2t a $l2t$1D %o2 $an often b2% a
new $12$/ wit1 inb2ilt $l2t$1.
T1e s$rews are self ta33in0 and mat$1 a P1illi3Ns 1ead bit in t1e drill. J2st 1old two 3ie$es
of wood to0et1er wit1 one 1and and drive s$rew in wit1 drill in ot1er. )ast = and t1e
s$rews $an be re=2sed.
If %o2 want to minimiCe t1e indentation w1ere t1e s$rew 1ead meets t1e 3l%D 2se a
3l%wood 3ad alread% 3la$ed on s$rew. If 0l2in0D t1e 3ad s1o2ld 1ave some 3lasti$
3a$/a0in0 ta3e wra33ed aro2nd it to sto3 a$$idental bondin0 to t1e wor/3ie$e.
I mass 3rod2$e t1e 3ads b% $2ttin0 a stri3 of 3l% F2s2all% +mmD 8A#I t1i$/G abo2t 87mm
wide F3A#IGD $overin0 one side wit1 3a$/a0in0 ta3eD t1en $2ttin0 it into 87mm F3A#IG
sE2ares
6et=on=6et Coatin0 and Dewa;in0 C2red E3o;%.
-reat im3rovements 1ave been made to !ote Cote brand e3o;% in re0ards to t1is
3roblem. It is ver% 2nli/el% to o$$2r at all. All t1e 3re3aration %o2 need for t1e ne;t
3ro$ess is to sand t1e 1ardened e3o;% s2rfa$e. T1e wet=on=wet a33li$ation met1od is still
t1e best as %o2 donNt 1ave to sand between t1e $oats.
5owever ot1er brands of e3o;% ma% s2ffer from wa;.
As e3o;% $2res some of t1e 2nrea$ted $om3onents mi0rate to t1e s2rfa$eD leavin0 a wa;%
resid2e.
T1is $an red2$e t1e ad1esion of followin0 $oatsD w1et1er e3o;% or 3aint and ma/e t1em
0o Ifis1=e%edI Ft1e s2rfa$e finis1es 3ittedG.
T1is is w1% I alwa%s 2se a Iwet=on=wetI e3o;% a33li$ation met1od Fsee Ie3o;% $oatin0I
aboveG. If t1e s2rfa$e is allowed to $2re it will 1ave to be dewa;ed Fnot !ote=CoteG and
sanded F!ote Cote tooG.
De-a<i(4 = 61en t1e two to t1ree $oats 1ave $2red I alwa%s de=wa; t1e s2rfa$e 2sin0 a
3lasti$ domesti$ s$o2rer FS$ot$1briteG and water wit1 some $lo2d% ammonia added.
S$r2b ver% t1oro201l%.
'o2 $an t1en sand t1e s2rfa$e to /e% it for f2rt1er 3aintin0D e3o;%in0 or 0l2in0.
)illetin0 and -l2in0 2sin0 >Sna3 Lo$/? Plasti$ !a0s
ost s23ermar/ets 1ave varieties of >sna3 lo$/? ba0s. T1e% 1ave a seal a$ross t1e
o3enin0 of t1e ba0 t1at $an be 3ressed to0et1er wit1 fin0er3ress2re. T1e% ma/e it a lot
@ i$1ael Storer 8.
easier to /ee3 e3o;% 0l2e awa% from areas on t1e boat w1ere %o2 donNt want to 32t it.
And also areas on %o2rself w1ere %o2 donNt want to 32t it:
a/e 23 some e3o;%D t1i$/en it to t1e $onsisten$% of 3ean2t b2tter. P2t a Isna3 lo$/I
-lad 3lasti$ ba0 into a tin and fold t1e to3 of ba0 over li3 of tin Fli/e a 0arba0e ba0 in a
0arba0e bin = tras1$anG. S$ra3e e3o;% into t1e ba0.

Ta/e ba0 o2t of tinD seal o3enin0 and $2t one $orner o2t of ba0 to ma/e a 1ole a few mm
Fa33ro; 8A#IG a$ross = siCe will need to var% wit1 $onsisten$% of mi;.

!% 0entl% sE2eeCin0 t1e ba0 a bead of e3o;% will ooCe o2t of 1ole in $ontrolled wa% from
t1e 1ole.
Pi3e a bead of e3o;% down t1e ri01t an0le between t1e b1d and t1e sidesD a$ross t1e
$1inelo0 and bottom. T1e bead s1o2ld be abo2t 82mm a$ross t1e ba$/.
(se a filletin0 sti$/ of a radi2s t1ree times t1e lesser 3l% t1i$/ness to smoot1 down t1e
fillet. Pra$ti$e 0ettin0 it smoot1 and even.

"emove e;$ess from eit1er side of fillet wit1 a stirrin0 sti$/ t1at 1as been s1ar3ened to a
$1isel 3oint. It is 3ossible to la% mas/in0 ta3e down eit1er side of t1e Moin in t1e first 3la$e
so t1at t1e e;$ess $an be removed wit1 t1e ta3e.
-ivin0 'o2rself Time
If doin0 lar0e areas t1e e3o;% will 0o off too E2i$/l% if left in t1e mi;in0 tin. 'o2 will 1ave
m2$1 more wor/in0 time if %o2 3o2r most of it o2t over t1e s2rfa$e first and ro201l% s3read
wit1 a sE2ee0eeD before 0oin0 ba$/ wit1 a roller to s3read 3ro3erl%.
T1is allows t1e 1eat of t1e e3o;% rea$tion to es$a3e into t1e air. If t1e e3o;% is mi;ed and
left inside a tin it will over1eat and 1arden in 8* min2tes. If %o2 0et it o2t onto t1e s2rfa$e
reasonabl% E2i$/l% %o2 will 1ave 1alf an 1o2r to 3la% wit1.
61en it is s3read 1old roller so it $annot rotate and 32ll 0entl% alon0 s2rfa$e of e3o;%. It
sli$/s t1e s2rfa$e smoot1 and 3o3 an% air b2bbles.
61en first $oat 1as be$ome E2ite ta$/%D roll on se$ond $oat. Sli$/ t1e s2rfa$e.

61en se$ond $oat is ta$/% roll on t1ird Fif reE2iredG and sli$/ it down.
IPO"TANT = "emove mas/in0 ta3e w1en t1ird $oat is still ta$/%. 'o2 donNt want to 0l2e
it down = forever.
If %o2 1ave 3roblems 0ettin0 a 0ood finis1 s3ea/ to %o2r e3o;% dealer.
!2ildin0 stron0 li01twei01t boats and items = a note on t1e 2se of e3o;%
E3o;% is e;3ensive st2ffD so w1en t1ere is a bit left over from a 3ro$ess t1ere is a
tem3tation to 2se it somew1ere.
DonNt do it: T1e boat 1as been $aref2ll% desi0ned to be stron0 eno201 alread% = all %o2
@ i$1ael Storer 84
will do is add wei01t and r2in t1e boat. 61ere %o2 $an 2se it for a le0itimate ste3D do so =
b2t t1in/ abo2t it first.
Anot1er time it is best to t1row o2t e3o;% is if it is startin0 to 0o off in t1e ba0 or tin. If it is
startin0 to 0et too 1ot to $omfortabl% 1old it is 0oin0 to be 1ard ver% s1ortl% = %o2 are
2nli/el% to 1ave eno201 time to 32t it into 3la$e.
)2rt1ermoreD 1ot e3o;% fillets sl2m3 badl%D 1ot $oatin0s wa; and 0et fis1=e%e 3ittin0D and
1ot 0l2e Moins end 23 wit1 l2m3s t1at sto3 $lam3in0. a/e 23 a smaller mi; ne;t time and
0et it o2t on t1e s2rfa$e earlier strai01t after $aref2l mi;in0 in t1e tin or ba0.
@ i$1ael Storer 87