That's a long skinny canoe
Some assembly required
Kit from www.newfound.com
First stem laminated
Both stems laminated. Each stem lamination is made up of 10 1 inch wide 3/16 inch thick 4 feet long pieces of wood. Five pieces are laminated to form the inner stem closest to the form. Five pieces are laminated to form the outter stem. Inner stem is visible inside the canoe, outer stem is visible outside the canoe in later pictures.
Monofiliment line is streched the length of the forms to align the center of each form so the final center line of the canoe is straight
Duct tape will prevent glue from sticking to the forms hopefully making it easier to remove the canoe from the forms later
Inner stem ready to be shaped to have cedar strips glued to it. The stem is tapered to 1/4 inche on the outer edge with 1/4 inch cedar strips later glued to each side the final dimension will be 3/4 inch. Then the outer stem is epoxied to it and shaped to the strips.
Stipping of the 'football' patch
This will be custom fit into the opening left when the side stripping meets a the top of the forms (bottom of the canoe)
First strip layout took a while
Finally, first few rows on one side. Darker blotches are from wiping the glue squeeze out with a wet rag
Close-up of the first few rows. Darker blotches are from wiping the glue squeeze out with a wet rag
Close up of transition from western red cedar to northern white cedar. The two narrower (1/2 inch) accent strips are aspen. Repeat northern white cedar strips from here to the football patch on the bottom
Another couple of strips added tonight
A view of the other side
Dry fit the sheer line parts near the stem. Need to make four of these
Lots of work to do smoothing out the stem to make room for the outer stem. Then repeat the work at the other end.
Two 1/4 in strips and the 1/4 inch edge of the inner stem
Closing in on the bottom of the canoe where the football patch will be fitted
Inner stem completely covered by the strips
Stripping Completed. Just need to wait for the glue to dry
All strips are glued Time to fit the 'football' patch
'Football' patch strips glued together sitting on top of the opening From inside the hull trace the opening onto the darker glued together strips to get a rough cut of the patch
Rough cut away the left side
Rough cut away the right side
Make some marks on the hull and on the patch so I can repeatedly get it back into the same position
Rough cut away the point of the 'football' patch The patch is still sitting on top of the hull opening
Now the tedious process of precisly fitting the rough cut patch into the fixed opening in the hull. That is fourteen feet of edge to trim, sand and tweek to match the fixed size opening, all while keeping the previously fitted edges perfectly lined up...this could take a while
Outer stem epoxied, time to let it cure for a couple of days
You didn't think the screws would stay in did you?
Rough marking for shaping the bottom of the stem
Start shaping by cutting off bulk of the bottom
Cut off part of the curve
Moving right along on shaping the outer stem
Getting closer to the final shape of the stem
That looks about right
One outer stem shaped Now match the shape on the other end
Need to come back later, drill out the screw holes, fill them with dowels then do the final shaping and sanding I have not decided if this is the bow or the stern
First coat of epoxy applied!
Straps are holding the keel in place while the epoxy cures
Keel in place waiting for epoxy to cure
Keel epoxy has cured now time to add a layer of epoxy over it
Keel fiber glass before wet out
Keel fiber glass wet out done. Let this cure then fill coat the entire exterior.
Final coat of expoxy on th exterior! Tomorrow we flip it over to start work on the inside if I can find a helper Any volunteers?
I tried to clean up the glue squeeze out as I went along, looks like I missed a bunch. Time to scrape off all of the glue and sand the interior
Interior ready for sealer coat of epoxy
Sealer coat of epoxy done on the inside
Let this cure then sand it and apply the fiberglass to the interior
Stems were fiberglassed during the sealer coat on the interior
Another shot of the interior with sealer epoxy coat and fiberglass on the other inner stem
Interior fiberglass layout
Interior fiberglass wet out has begun
Stern interior fiberglass wet out done
Interior fiberglass wet out done (3.5 hours after starting). Inner gunwales are clamped to the rack so the scuppers could have the second coat of epoxy applied. Much easier to apply epoxy to the scuppers before gunwales are installed.
Excess fiberglass trimmed
Close-up of interior fiberglass. Textured finish will be left to provide traction.
Inwales dry fit looks good
Starboard side inwale epoxied in place. Leave the clamps on for a couple of days to let the epoxy cure then epoxy the port side inwale.
Inwales permanantly affixed to the hull
Port outwale epoxied clamp for two days to cure
Closeup of port side outwale and inwale
Once the outwale clamps come off these three deck pieces will be laminated and bent to match the contour of the hull, clamped for a couple of days then cut to fit in between the inwales and epoxied in place. Same process for the other end of the canoe.
Decks laminated. Wait two days for epoxy to cure, remove clamps and fit to the openings.
Side view of one of the laminated deck clamped to lock in the curve
Stern seat support blocks epoxied to the hull. Wait two days and remove the clamps.
Bow seat blocks clamped in place and bow deck clamped in place
Decks, seats and yoke dry fit. Time to epoxy the decks into the hull.
Final coat of epoxy on gunwales and decks. Epoxy is done! Interior is sanded and ready for two coats of matte finish varnish. Exterior needs four sanding sessions in preparation for 3-4 coats of high gloss varnish. The finish line is in sight.
The first of four coats of varnish is on!