Wednesday, 27 June 2012

Fr 7 almost done

Frame 7 continues

First thing to finish was the aft doubler top piece to join to the curved laminated beam.  Used a piece of cardboard from a breakfast cereal packet as a template, then cut from two bits of a previous frame that I made a mistake on and had to redo.  Lucky I didn't burn them with some other scrap.

Finished all the solid vertical wood bits, then it was time to pull everything off and epoxy glue and screw it back together.

Below are the 12mm ply joiners that go from the 30mm x 45mm vertical wood to the laminated beam.

Below shows the four vertical 30mm x 45mm bits with a 20mm x 45mm cross piece that forms part of the engine space framing.

Below is looking from aft.  The four ply bits are on the forward face of the laminated curve, you will see them when I finish it up and put a few close ups in the next post.  On the left and right solid wood frames you can see the doublers finish between the ply webs and the bottom hardwood cross piece.  The large spaces above the ply each side are the berths that go under the cockpit, the cabin seating forward of this frame also being part of the berth.

The vertical rectangular spaces formed inboard of each of the berths will be storage, one side for batteries and other bits and pieces, the other as a hanging locker for wet weather gear.  There is a packer piece between the outside vertical wood and the front ply web the same thickness as the solid frame each side, you can see where the clamps are top and bottom inboard edge of each ply web holding it until the epoxy goes off.  

The square shape in the middle is the engine space (around 10hp marine diesel with alternator for charging batteries as well).  It will go from just inside the cabin, through this frame to frame 8.  The space above that is a storage locker accessible from the cockpit.  I had some epoxy left over, so filled the screw holes on the back of the laminated frame (14g x 50mm) and the four screws each side (10g x 30mm) on the wood doublers.  I hid the holes inside the berth so they would not be visible from the cabin, but they probably wouldn't show through the paint anyway.

Next post will be a short one showing the final result with a few close ups.  This was one of the most complicated frames on the boat so far, frame 8 also has a bit more work in it than the earlier ones.

Sunday, 24 June 2012

Frame #7 part one

Frame #7 is underway, but this one is a lot more work than the others.  For a start each of the side solid sawn wood frames has doublers front and rear.  This makes for 75mm thick of clear Hoop Pine each side, with plywood web down the bottom.  Also my first laminated beam makes an appearance, and actually fit fairly well.

First off was to try and remember my high school woodwork skills, and cut rebates in the solid wood base.  Below is looking from the forward side.

Close up, the rebates are for 30mm wide x 45mm deep vertical frames.  Outside ones slope from rear to to front bottom, and then a 20mm rebate on the bottom is cut full width.  Inside two are just top rear to front bottom.

One of the outside ones from aft showing the 20mm high rebate.

Then the solid sawn frames.  There are doublers front and rear, making these 75mm wide in my case.  Unfortunately that means three scarf joints per side.  I decided to add screws for extra strength, and also to hold it all together while the epoxy glue set.

WARNING: the laminated beam was supposed to be screwed and glued to the rear of the frame before the forward doubler went over the countersunk screws.  Don't stick it together too early!  I did, thinking it would be easier to get it into one piece, without checking the plans.  I have screwed through from the rear of the laminated beam and I don't think it will make any difference (I hope).

Below is the forward side, a bit hard to see but the doubler ends short of the inside of the frame itself to allow a plywood web to be screwed on.  I will show a close up on part two.

Aft is below, note top doubler to meet the laminated beam is yet to be done.

And the width:

Below is the start of the dry fit, don't worry the wood is straight and even it is just the angle I took the photo at.

More to come, there could be a little delay in finishing though with school holidays. Call it intermission.

Saturday, 16 June 2012

Frame 6 - but I lied

Fr #6 is complete, but fr #5 was not the widest. When I was marking this one out I found it was 2704mm frame outside to outside (76mm wider than the last one). A few tense moments as I flicked through the plans of the frames to come and confirmed THIS was the widest. By my calculations I only have 75mm each side of the completed hull to get it out the door, so you can understand why I ran into the house!

Below is one side of this frame. It has no hardwood across the bottom as the two layers of ply to go across on top (when upside down) make up the main cabin area. Apologies if this is too confusing, scroll down to the bottom and imagine the completed frame upside down and it will make sense I hope.

The 9mm ply web at the base forms a seat support, the 6mm ply at the top goes all the way down to 9mm above the bottom ply web (for a seat top to slide into). 9mm doubler on this side from the bottom of the bookcase across the frame scarf joint again stopping 9mm above where the seat support is. 

The top 6mm ply forms the framework for a bookcase, with 20mm x 20mm solid wood doublers each side. The horizontal ones support the shelves, the vertical ones give you something to screw the ply front onto. Notches for 20mm x 20mm running length ways for the front to attach to between frames.

Below is the finished frame, from aft:

And forward side:

Those with good eyes will notice on the right hand side there is some solid 20mm x 20mm missing (bottom vertical of the front support). I did a dry fit before removing each lot of the bookcase supports individually and putting on the epoxy. 

The next day when I pulled all the clamps off one handed while patting myself on the back there was the sound of wood hitting the concrete. Missed one on each side and had to mix a very small batch of epoxy (did two other little bits I had neglected on an earlier frame as well). Just when you think you are starting to get it together you are reminded of just what an amateur you are...........

Saturday, 9 June 2012

Frame 5 - Half Way (almost, then transom)

Frame 5 was slightly modified from the plans as I am replacing a work table/storage area on the stb (right) side into an enclosed head (well that is the plan at this stage anyway).

Below is lofting it out, the ply is for the port side and is the rear face (aft side?) of the galley.  All will be clear in a minute.

Below is a close up of the modification. This side (stb) is also supposed to have 12mm ply web.  I put a 12mm doubler on to stiffen the solid frame wood, and will put a solid piece of wood between the hardwood floor and laminated overhead beam when fitting out to frame in the head.

Below is with the epoxy setting, has already been screwed as well on the hardwood cross piece.  The ply is 12mm again.

Below is a close up of the inside of the galley.  The rectangular section on the left is the inside of the day water storage area.  The middle piece will have two draws at the top and the bottom is ventilation and storage space.  Far right area I will find a use for.  On top of the horizontal piece of 20mm x 20mm will be a ply bench.  When the ply is continued up to the cabin roof there will be a large galley access hole cut so you can lean in from the main cabin to use it.

Below is the completed frame looking at the aft face, width is 2628mm to outside of the frames with hull planking and rubbing strakes (?) to come yet. This is the widest frame of the boat. Don't worry about the wood taped to the ply, it is framing for the seating/berth that continues aft but I am considering some changes so didn't attach it yet just in case.

Imagine standing about where the wood is taped on and leaning in through a hole that is almost as wide as the sheet you can see.  Probably too confusing, just wait three years and you will see what I mean....

Below is the forward face of the ply.

Tuesday, 5 June 2012

Frame 4

The frames continue on, I will not put too much detail in this post because the scarfing etc is all the same.  This one is bigger but similar to the previous frame being 2490mm across and 12mm ply which is much heavier.

Below is the laminating after cutting all the wood.

Below is the rear face, I will cheat and cut the description from another thread on the woodenboat forum - below is the forward face of the galley, middle is access to forward where the bed/berth will be. On the right will be the forward wall of the enclosed head. Both these will have ply fitted above the horizontal joiner once the boat is completed to hull stage and flipped over for fit out. Lets not get ahead of ourselves yet though.....

Forward face below, note hardwood cross piece.  Leaving it without any fit out as I am thinking about a few things regarding storage and where to start/finish the double berth.

Finally below is a shot of the first four frames done, they are starting to get extremely wide.  I visualised it and measured it out, and even drew scale drawings.  But until you make a few you don't get an idea of just how wide this thing is going to be.

Friday, 1 June 2012

Frame 3

Next frame has been completed.  Below are the shaped solid wood, showing the scarf joints, with the cardboard templates just visible in the top right hand corner.

This one has 9mm ply webs on each side against the solid wood which will form part of storage dividers and also support the double berth in the front.  You can see them below, they were cut oversize and then after clamping the solid the ply was marked for cutting the curve.

Then the solid wood and ply were epoxied together, clamped to hold them flat.

Now the sides were solid, the frame was placed on the lofting floor, propped up and had the hardwood cross piece screwed ( 14 gauge x 40mm)  and epoxied together.  A temporary cross piece was screwed across the top to give it support and also for placing on the strongback upside down.

Below is the rear face, I had some epoxy left over so coated the ply each side a bit up from the solid wood/hardwood cross piece.  Width at the top to outside 2340mm.

Close up of the right rear:

Finally the forward face: