Monday, October 20, 2014

Rebuilding the Square Meter: fitting the keelson

We took the keelson home to our shop to do a little work on it.
We laminated on an additional 1 x.  This will strengthen it and enlarge the rabbet.  This will help when it comes time to plank.

After the epoxy set up, it was back to the barn to fit it.  The framing tails were built a little long so we snapped a line and cut them.

Once the keelson was set in position, it allowed us to fit in blocking for the keel bolts.  These blocks raise the bolt head up a bit in the bilge. They also are cut with a bevel to provide a flat level surface for the bolt nut.  Additionally they provide a little more beef to hang the lead keel on.

Here are photos with descriptions.



Here is the keelson with the additional lamination of oak.
It is 5.5 inches wide at it widest point and about 3.75 inches thick.

This is the stern end.  The rabbet is now about 1.5 inches wide.  The funny looking ends will be whittled in place.

We used thickened epoxy with hardwood pegs for all the laminations.

The is the underside.  It will receive the lead keel.


The frames are beveled to fit the keelson. Blocks are added for support for the keel bolts.

When the keelson is through bolted to the frames, this will suck up nice and tight.

The bottom end is taking shape.

Friday, October 10, 2014

Rebuilding the Square Meter: fitting in the new frames

Today we did the fine sanding to get the new oak frames to fit well into their spots.  By fine sanding I mean 36 grit on a angle grinder.  It takes off the wood quickly and provides a nice abraded surface for bonding.

Once the frames fit well, we roughed up the mating surface of the hull, mixed up epoxy and thickened it with colloidal silica.  At a later date we will add bronze fasteners through the planking.

The frames are bonded in and on the next visit, we will refit the keel timber.  Once we like the fit, we will use a ship auger to drill out the frames and timber for stainless steel through bolts.





Wednesday, October 1, 2014

Rebuilding the Square Meter: Hull framing

We are fitting in new oak frames to replace the rotted out bottom of this 1929 Swedish Skarrie.
Using some drawing paper sheets, we are making templates for each location.  Since the bottom of the hull is open, we are able to press in sheets of paper and trace in the hull curvature for each frame.
These lines are transferred to the 8 quarter oak and cut on the big band saw.
Any additional fitting is done with a angle grinder with a 36 grit disk.

We have finished three frames and today we are forming 4 additional ones.  The tails are slightly long.
These will be marked where they intersect with the keel timber and cut accordingly.  Once everything is fitted, long stainless through bolts will be installed the hold it together.




Marking the intersection with the rudder for a cut.



This barn is awesome.  It is framed in massive walnut!  It is wood peg post and beam construction.
Really well built.
We will use its framing to hoist the hull off it's trailer in the coming weeks.


This main beam is a full 12 inch square of walnut.
You can see the adz marks.
Here is the mast hanging off it.

Wednesday, September 24, 2014

Rebuilding the Square Meter: paint stripping

After 4 passes and 6 gallons of paint stripper, we have started to see the strengths and weaknesses of the hull.  This is a race boat and is built accordingly (light).  This is good for us.  The ribs will be easy to duplicate.  They are thin laminations of steam bent oak.  The lower braces are heavy oak but are not very large.  These will be recut out of 8 quarter oak and either directly replace the originals or be sistered in alongside the originals.
Here are photos of the work to date:
The stripped cockpit.  We used stripper to both remove paint layers in the bilge as well as to remove the canvas deck adhesive.

The most recent paint layer was battleship grey.  The early layers were way nicer.  A pale blue layer covered the original orangy red.  Now that's a factory color!



It looks nasty now.  Just wait.



Here is the cut out keel timber,  The top has a rabbet for the planking, the bottom is flat to receive the lead keel casting.
We are duplicating this piece out of oak.  Here is a piece of 8 quarter (2 inch thick) oak.  Additional oak will be pegged and epoxied on to build up the shape.

Here is the big oak passing through the Silver Band Saw.   Finally a piece  of wood
that is the right scale for the saw.  The saw ate through the wood like nobody's business.

Here are two pieces of new oak that we saw cut to shape.  Tomorrow we will bond them together
and continue forming the part.


Saturday, September 6, 2014

Rebuilding the 1929 Square Meter, Kippis: We got the job!

The owner liked the bid well enough to give us the go ahead.  Brave Man!
There are some unknowns we will discover but he is a fearless sailor.


The first items on the to do list were to take measurements of everything that might be removed.
The biggest thing on this list is the keel timber.  It has rot but nothing is missing, so it will provide us a useful pattern.

After the measurements were recorded in a new log book, we began the process of chemically stripping the bilge planking and ribs.


The worrisome hole in the bottom of the boat.



Saturday, August 30, 2014

Photos of our boards on the Maine Coast

Here Eifel is paddling past Victory Chimes, the beautiful schooner at anchor off Stonington, Me.
We had super calm and foggy conditions for our morning paddle.
Click on the image for a higher resolution version.


Hello?


Here is Don in his self built 18 foot wherry.

He kept us on course around Crotch island..

Eifel is enjoying the granite.



Sunday, August 17, 2014

Testing Testing

Our company (family) had the opportunity to take a long road trip up to the coast of Maine.  My goal was to test out our newly finished carbon board.  We took both the all glass Sea State 12 Sup and the Carbon 12 Sup.
On the trip, we stopped to visit family in central Pennsylvania and we took a 8 mile float trip on Bald Eagle creek.  This is a scenic tributary to the Susquehanna river.
The creek is very shallow in places.  Sups often have troubles with shallow rivers because of the fin.
Fin boxes or the fin themselves will break.  Also when a fin touches bottom, it is very likely you will tumble.
Our boards worked unbelievably well in this environment!  Our board is a hybrid of a displacement hull form but with rocker.
It might look a little odd to some but it has several advantages.
Upon approaching shallows, the rider gets on his or her knees toward the front of the pad.  This kants the board forward on its rocker profile.  The bow now sits in good trim and the back of the board is lifted about 3 or 4 inches out of the water.  It also pivots the attack of the fin so that when it hits any rocks it rolls over them.
It helps that our fin boxes are laminated in with a strong lamination of carbon fiber.
In the following video you will see this design feature in action.
Both boards are fitted with rigid 9 inch fins.  Not short rubber fins.  In the standing position, they provide great directional control.



 

Saturday, August 16, 2014

Sup in Casco Bay

Here Christa and TJ are paddling near Yarmouth, Me.
They are on our new carbon 12 footer having fun.



video

Wednesday, July 30, 2014

Shark gets a fin

Here is the new 9inch fin we just installed on our carbon board.


We finished our first carbon fiber 12 foot Sea State board today.
It is actually half carbon.  The hull is carbon and epoxy and the deck is gel-coated glass set in resin.
A carbon finished deck would be too hot to deal with.
To wrap things up with this board, we added a 9 inch fin.  Here are photos that show how a standard fin box accepts a fin.

Our fin boxes are laminated into the hull and we find and cut them open after the hull is molded.  Once it is cleaned up, the fin attached easily...

The new fin, fin bolt and regular screw driver sit next to the just opened fin box.

This is how the bolt slides into the channel.

Next, the fin slides into the channel toward the front of the box.
You tap the fin forward with the palm of your hand or a rubber mallet.

Next, the bolt screws into the pre-inserted nut and voila, it is done.









Tuesday, July 22, 2014

Old boat in a barn

I've heard of great barn finds of cars, but here in Missouri you never see this:
A 1929 Square Meter class Skarry.  It is a beautiful mahogany racer from Sweden.
Here is the Wiki link:
http://en.wikipedia.org/wiki/Skerry_Cruiser

Check it...




The owner called because he is interested in a restoration.
Sweet!





Sunday, June 15, 2014

The new Sea State 12 SUP is here

We took our new SUP out for a paddle this weekend and had a great christening.
Here are photos from our paddle around Horseshoe lake.
This first board is an all glass hollow board with carbon fiber internal supports.

It  is 12 feet long and 31.75 inches wide x 5.5 inches.
It is strong and rigid, also light for its size at 35 pounds.  Christa here is barely pressing it into the water with her pretty 110 pounds.  This board can easily handle riders in the 250 pound range.




Here I am paddling among the rushes.  My 190 pounds are getting the board into proper trim.




Here is a photo of the watertight deck compartment.
Great for storing the essentials (keys and phone).
Tie downs on the stern are great for securing anything else.