Post by juliangibraltar on Oct 9, 2014 10:22:19 GMT -5
Jensen, looking great, the rails are the biggest pain so once passed that it really starts coming together...! Heres a couple of pics of "Blair's Blocks" which saved me a lot of cussing when gluing the angles on the rails.....pre cut the blocks with 2 different angles, one at 45º and other around 67.5º (mine werent cut quite so precisely but you get the picture!) so it basically fits both angles on the rail and you can use them to clamp them down and keep them in place. Look forward to the next pics.
Also another gentle reminder that Blair mentioned was not to glue the rails only on one side and then all on the other as this might warp the bottom.....I'm sure you weren't going to do that but forewarned is forearmed as they say!
Thanks Julian. I was definitely kicking around the idea of the Blair blocks. I should have enough scrap kicking around the garage at this point.....and yes, I am definiteyl doing the stripping on both sides at the same time. Not going to build up one side and not the other.
All seems to be going well Jensen - must be all those good management skills coupled, of course, with good woodworking skills too.
I posted the paddle blade layout, in response to your question about size and angle etc, on my 'Inspiration build' page sometime ago I don't know if you have seen them yet. Nice pics, my how that Gorilla Glue foams - just like some sci fi movie!
I finished the second paddle just need to clean it up and then glass the blades etc. Maybe I can talk she who must be obeyed into letting me do it in the house where at least the temperature is high enough - otherwise it will be next summer!
Good luck with the remainder of the rails this weekend.
Post by jensen1031 on Oct 15, 2014 15:09:35 GMT -5
Hey everyone- wanted to post some pics on the progress that I have made over the past couple of weeks. I’ve been trying to write these posts as a tutorial for any newbies (like me) that are reading this for the first time. Learn from my mistakes on my first journey. Happy to report that the rails are finally all done. Pics below show both complete rails, and the one side, planed down to accept the deck. Will work on the other side tonight, but that will take some more work. Couple of learnings, and included some pics to show how I overcame them. 1) The Blair Blocks aren’t a “nice-to-have” - I would consider them essential. Julian was spot on how much they benefit the process. I would still be on the 3rd or 4th rail if not for them. 2) To that point, I didn’t get real fancy with the blocks. I simply cut 2-45 degree angles to give me the notch that was needed. It did the trick for me. 3) Unfortunately I had one rail pop off after it was glued down. Not really sure how it happened. I think there was a lot of stress on the wood. Instead of ripping off the whole rail, I tried a repair and I think it worked. Check out the pics. 4) I worked 1 rail on each side at a time vs. building up one whole side. Per Julian’s build that was to prevent warping. 5) One can never have too many clamps. I have 8 bar clamps and about 20 hand clamps. I would have rather had 20 bar clamps and 8 hand clamps. 6) On side was picture perfect with the diagrams. One side was not. I could not get that final rail on at the right angle. I don’t know if this was a function of bad cutting on the ribs or what. I fixed this by adding an additional rail that was split in half (.5x.5). This was small enough that I was able to connect the rails to the ribs for support. Will require a lot more planing as a result, but at least the structure should be strong. Next up is to plane the other side (not the picture perfect one) and to do some work on the nose and tail blocks. Will also be adding wood to support the fin box. You may see in a couple of the pictures some foam around the middle of the board. I had some extra spray foam that I wanted to try to see how much I would need. A few of you have done this. Any recommendations on BRAND of foam and also a ballpark quantity? How much weight does this add overall? Other than avoiding a vent plug, does it add to structural integrity (Im guessing yes)?
Post by juliangibraltar on Oct 16, 2014 3:32:45 GMT -5
Looking really good Jensen, nice fix on the rail. One bit of advice from another newbie on planing the rails......plane them flat on top to receive the top planking, don't get carried away like i did and try and plane an angle - as this causes some problem when laying up the top planking over the rails area. If you imagine, they are coming out from the centre relatively flat and then suddenly the last one is angled down the side reducing the contact of wood on wood over the rail. Plane it flat, glue it flat and then you have more depth of "glued" wood to plane the curve in the rails when all is done. My mistake (not a huge one but certainly a learning not to get over excited on planing the rails down!!).
Re the expanding foam i used it also as did 1975. In terms of quantities, i cant remember but I know I bought 4 big cans (dont know the size) and then had to go out to get some more but it didnt interfere with the process so you can always go back to it (basically because the way I did it was by sections). I think 1974 laid the foam, sanded it and then placed the boards, the way I did it was to lay some boards until I got close to the rails and then filled with foam (having braced the top deck so it wouldnt burst. This worked for me and made sure as much of the wood was "stuck" to the foam as possible leaving only the last 2 deck planks to place after sanding down the foam (I placed the deck planking one by one which was much better for a good contact as my cutting was no way near good enough!!).
Post by jensen1031 on Oct 26, 2014 20:21:20 GMT -5
Hey guys, long time, no check in. Still making some progress though. Images attached as always. • Rails are finally all done and planed down. I also trimmed the edges, so now I am able to see the final dimensions. What a difference that little haircut made. • I cut the bottom and prepared it to accept the tail blocks. Also drew out and started to build the nose and tail out of the cedar and sapele alternating layers. • I spent a lot of time working on things for her “undercarriage.”I fit blocks for a handle and the fin box. Also placed blocks at the nose for a FCS and leash cup. This will be for a GoPro camera mount that I found. • I am building my own leash cups off of some of the designs I saw on this site. I am going to put 4 up front for a cargo tie down and also 4 in the back for fishing gear. I have them all built and the metal rod epoxied in. Just need to grind down the little nubs where I glued in the rods. • I opted to use foam vs. vent plugs. I have the hull filled and just started to shave the excess. Messy messy. o For those that want to know HOW MUCH you need, I ended up using 10 cans of GREAT STUFF, large gap foam filler. Probably could have gotten away with 8 • Lastly, I am finally getting to the top skin. I have the center stripe glued down and the other pieces cut.
Great stuff Jensen looks like you've been busy. All down to shaving the foam and fitting the strips on the deck now. After that it really starts to look the part and gets even more exciting. How's the temperature holding up over there by the way?
Also, I don't know if you received my message but the paddle size, off sets, etc, are under my last posting on my own Inspriation blog.
Post by jensen1031 on Oct 27, 2014 10:05:52 GMT -5
Thanks Timbo. Yes, I did get the paddle dimensions and link from your other post. I actually cut the staves this weekend and then proceeded to decimatre them trying to cut that birdsmouth. I finally had to raise the flag and have my father in law help me this coming weekend. Your paddle measurements worked perfect for the template. Will send pics once that starts to look presentable. I spoke in "a language the clergy do not know" trying to cut those birds mouth pieces
Weather so far has been typical New England fall. Frost in the mornings and spring like in the afternoon. Luckily I have a propane heater in the garage that keeps it pretty cozy. I am awaiting the leaf apocalypse in the next couple of weeks. Unfortunately, glassing will have to wait till spring.
Im planning on making a 9' board for my wife, so in the meantime when I move this behemoth to our basement I can get some work done on hers and in spring glass both of them.
I had problems trying to cut the birds mouth with a bench saw so in the end I used my router with a 90 degree V bit set up in my homemade router table. So much easier, worked first time and each one was perfect. I thought I would have trouble gluing them together in an oval but used Titebond III and some rubber bands and they all stayed in place. I then used tape about every 6 inches until they were dry.
When finished the difference in weight was very noticeable compared to my solid shaft one. The only problem is that the oval section is a little bigger than I would have liked and if I sand it down anymore I will probably lose some structural integrity.
Good luck and keep posting and collecting leaves!!
Post by jensen1031 on Oct 29, 2014 13:14:17 GMT -5
Good idea on the router table.....unfortunately thats the one tool I dont have. But hey, Christmas is coming, right?
Im going to make a zero clearance jig for my table saw. Something I should probably have anyway. Let me see if that makes any difference. If not.....well I just made my wife's shopping list a lot easier.
Ill post pics later, but i have 5 strips on the top skin already done and on the rack clamped down. No reason why i couldnt have the top all done tonight. So far it has been a very easy process. Only change that I would make is with the foam. I think that Julian's method is more effective. Put on almost of the strips and then spray the inside so that the foam goes everywhere to fill the space.
I just spraed the foam before putting on the top deck. I had a lot of waste, and I now I find myself injecting foam back in becuase I cut out too much. I wouldnt be nervous about the foam pushing up on the boards since I have that clamped down so tight. Nothing is coming out of there.