And So It Began
Jim March 12th, 2007
Shop class presents an image of stasis that runs directly counter to what Richard Sennett identifies as “a key element in the new economy’s idealized self: the capacity to surrender, to give up possession of an established reality.†This stance toward “established reality,†which can only be called psychedelic, is best not indulged around a table saw. -Matthew B. Crawford in The New Atlantis
Construction on the boat has officially commenced! Last weekend, I entered the shop on Friday night and didn’t exit until Sunday evening, outside of tending to my necessary life functions (you know the ones …). Here’s the play-by-play, which I’ll try to make as interesting as I know how:
Epoxy: On Friday, I began by gluing the necessary boards together for the transom and stem. The transom is made from three layers of 1/4″ marine plywood, bonded by epoxy. The stem is made from 1 1/2″ thick lumber, or in my case, two layers of 3/4″ thick sassafras, glued together
I had never worked with epoxy, so I did my best to read everything I could about the stuff. Of course I had a copy of The Epoxy Book (requires registration to access) by System Three, but I must say, I found it unhelpful. Instead of discussing the practical application of epoxy, it was full of words like ‘thixotropic‘ (of which I have only a passing, pedant’s interest), and marketing for their SilverTip Marine Epoxy Series (which I had not purchased). Luckily I had stopped by my local West Marine and picked up a publication by WEST System simply called User Manual. This little book proved to be invaluable, and I can’t recommend it enough.
The WEST User Manual recommends a two-stage bonding process where one coats both surfaces with unthickened epoxy resin and then applies thickened epoxy on top of this base coat, in order to reduce the chance of creating a resin-starved joint. I did this when working on the stem and transom. While I’m sure this helps accomplish its stated goal, let me tell you: it’s a real pain. You mix up the resin and hardener, apply it and get it all over your gloves, then you have to take off you gloves so you can reach into the plastic mini-fibers container and thicken your remaining epoxy mix. Do you then put back on the same epoxy-covered gloves, exposing yourself to its toxins in the process? Or do you waste another pair of gloves? I think for my next epoxy job, I’ll either opt for a single-stage bond or I’ll make sure to have plenty of thickener set aside in an open cup so that I can add it without removing my epoxy-covered gloves.
Stem: The stem was easily the part that I was most concerned about getting right, and so I probably spent more time on it than I should. However, it actually proved to be no big deal. A few cuts with the band saw, a few swipes with the my Stanley Type 18 No. 5 Jack Plane (I’m becoming a bit of a plane geek), and voilà ! I did put a few nasty nicks into the face, but no one ever sees this part so it’s no big deal.
Notice the nice curly grain on the stem. Too bad no one will ever see it.
Transom: This part proved to be pretty straightforward too. It’s not quite finished in the photo below, but you get the idea. At present, it is only 1/2″ thick, but the third layer won’t go on until all the planking is done. I used the worst piece of marine plywood I could find for the middle layer, since all those nasty defects will be hidden from view.
Temporary Frames: Finally, I was also able to get a good start on the 4 temporary frames required for Sand Dollar. Arch Davis provided full-scale plans for the stem, transom, temporary frames and bulkheads. This sheet is printed on Mylar, and to make these various parts, one simply lays the stock under the plans and pokes holes with an icepick in the plans, marking the various verticies on the stock. This worked great for the transom and stem; however, the temporary frames are made from particle board. I soon discovered that it was impossible to locate my pick marks on this material. However, Pops soon interjected with one of his frequently brilliant ideas: carbon paper. He happened to have a sheet lying around, so I was soon tracing the lines directly on to my stock, and grudgingly admitting that my dad is a genius. This would’ve worked well for the decorative cut-out at the top of the transom too.
The almost-finished temporary frames, mounted for installation into the strongback.
- Boat Building , Boats , Epoxy , Plans , Tools
- Comments(2)
thank the lord this isn’t being built in my dining room… way too much dust
Carbon paper? Almost as brilliant as M. B. Crawford.
Yeah, that does look like a lotta dust. Divine influence, I’d be inclined to agree, is that only thing that’s kept this project out of your domicile.