BoatBuilding Cutting the Frames

BoatBuilding - Cutting the Frames
Originally uploaded by OzzyC.

Over the last couple of weeks, weve been constructing temporary frame pieces, which were cutting out of particle board. The reason were doing this, and the process behind what were doing will take a little bit of explaination, so be prepared for a long entry.

The reason were cutting these temporary frame pieces is so that were sure the hull is straight. If you look at the picture, you may notice two pieces of board... one smaller piece of board, sitting on top of the particle board. The smaller piece is the actual frame piece that will be in the boat when its put on the water. The hull goes much farther up than this though, so we are using temporary pieces during the hull setting process. Once the hull is set, we will remove the temporary pieces and install the permanent pieces, so that we can add the deck.

In order to cut these sacrificial particle board frame pieces, we started with a 4x8 piece of particle board. We set the actual frame piece on the particle board and clamped it in place. We then determined the center point and line of the actual frame piece and extended this center line through the particle board, so that we could measure needed dimensions. After measuring the center line, we extended the end-lines of the permanent frame piece up the particle board, and measured from the center line to the top corners. In order to make sure our cuts were true, we measured cross-angle. we then added the notches and cut it all out with a power saw, except for the notches, where we used a jigsaw.

Click here to see the video summary of what we did.

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Mounting Frame Pieces

Mounting Frame Pieces
Originally uploaded by OzzyC.

Weve begun to mount the horizontal (port-to-starboard) frame pieces. There are six in all, and yesterday we mounted three.

We started by temporarily removing the stringers. This was Gregs idea, and I saw no need to keep them mounted, so they were pulled down. Next we measured the distances for all of the frame pieces, relative to the rear transom, and marked these distances on the building frame.

Next, we used the laser level to find the horizontal mounting point. We lined up the laser level with the reference point on the rear transom that we created a few weeks back. Next, we ran a piece of string down the bow-to-stern center line. This way we have the horizontal and vertical points of reference on each frame piece accurately measured. (You may remember that we drew these reference points on the frame pieces when we constructed them.)

Next we screwed 2x4 jigs into the building frame, in preparation for mounting the frame pieces to these same 2x4 jigs.

Next, we set the frame pieces on a floor jack, and lifted the jack to the correct height and center. This allowed us to make fine adjustments and get the frame pieces accurately placed. Once we lined up the horizontal points of reference with the laser level, and the vertical point of reference with the string, we screwed the frame pieces to the 2x4 jigs. This process went very quickly.

NOTE: Once we got the second frame piece mounted, we reset the stringers in place, knowing that it would be difficult to place them later.

Click here to see the video summary of what we did.

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Mounting the transom to the frame

Transom mounts
Originally uploaded by OzzyC.


Rear Transom Mounted
Originally uploaded by OzzyC.

Last weekend we mounted the rear transom to the working frame. We started by constructing the vertical frame mounts. The vertical frame mounts were built from the bottom up, using 2x4s screwed to the 2x6 frame on the floor, and then screwing the two angle-cut 2x6s to the 2x4s. The angle-cut 2x6s are cut to the same angle as the stringers where they attach to the transom. This is shown in the first picture.

Next, we mounted the rear transom to the angle cut frame piece with screws. When you put the transom on the frame, make sure its level and that the angle cut mounts are placed an equal distance from the center, and in a place that wont interfere with construction.

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The Frame is Finished

Yesterday Greg and I put the finishing touches on the frame -- unless he decides to re-tweak, which he often does. We shimmed all of the areas where there were loose joints on the temporary frame. Were now ready to lay the hull. Next week, we will be in Northeastern Wisconsin, for our annual canoe/whitewater kayak trip, so there wont be any working on the boat. Instead, well be playing in the canoes we made last year and paddling our kayaks.

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Boat Frame III

Boat Frame III
Originally uploaded by OzzyC

I havent forgotten about you or the boat. Its simply that were operating slowly this winter. Were close to flipping the boat, so theres not much to do other than build the cradle for the flip. As you can see from this picture, the cradle is nearly finished. Once the snow melts a bit and the weather warms a little, well flip er and get back to work.

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Its starting to look like a boat

BoatFrame
Originally uploaded by OzzyC.

This week, we set the rest of the sacrificial frame pieces in place, using the same process described in last weeks entry. This photo shows the full skeleton of the boat, and based on the shape of the skeleton, you should now be able to mentally picture the shape of the hull.

At this point, the stringers and sacrificial frame pieces are not precisely set in their final position, but theyre pretty close. Some of the notches are too wide, too deep (or too shallow), or some combination thereof. But again, its pretty close.

Next week we will do more precise adjustments of the frame by cutting the too-shallow notches a little deeper, and shimming the areas where theres too much slop. That process will likely take a couple of sessions, because were picky on precision.

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Flipped Out!

We got the boat flipped, but it was a day where everything that could go wrong, did. Okay, not quite "everything." Nobody was hurt, and the boat is still in one piece. But it did take five guys four hours to get her rolled.

Ive been waiting to roll this boat for years... literally! Weve been sanding and fairing for so long that I dont remember what its like to not be in sanding and fairing hell. Now, after years of making the boat look right, we can continue the structural and functional construction.

Heres a link to a video I made, consisting of photos and comments.

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