Building the frames

The plans called for building a complete set of molds, stripping the hull, and then, apparently tearing out all that perfectly good wood, leaving an empty shell... with no reference points at all. Other plans I had seen incorporated some form of useful station spacing. The various bulkheads and partitions were used as molds. The molds would become frames, and the frames would stay in the boat and provide structural reference points for the interior spaces. The frames were laminated from 1/2" Exterior plywood. 3"s across and 1" thick.


The anchor locker bulkhead was moved back to station #8, allowing for lots more 5/8" rode and a 30/35 lb. anchor.
The cabin's forward bulkhead was moved back to station #7, a closet floor at 3' above the sole would allow space for a chain locker below, lower and more toward C.O.G., and a huge closet at the forward end of the cabin. There'll be a hawspipe leading to the chain locker, and a trapdoor in the closet for access.
The cabin's aft bulkhead was moved to station #4. (The stations are 2'4" +/-.) The main (and only real) berth would become 7'1"+/-, instead of 6'1"1/2, leaving room to sleep like a human instead of a pretzel.
    The U-shaped galley was moved stations #4 & #2.
  Nav. station between stations #2 & #1; lockers, between #1 & #0.
    The Head: between #4 and #3, and a quarterberth between #3 and #0.

I began the process of sawing each station line out, starting with the largest, #3, then #2, #1 and so on, whittling away at the master pattern. (I had to do this twice. First to cut the station line, and again after deducting the thickness of the hull from the pattern. I didn't figure out that the lines were for the 'outside' of the hull until I had already finished all the lofting.)

Lisa, "The Soul of Patience" holds up #3, the First completed Frame.

Assembly continues with frame #2.

Building the frames took 10 sheets of plywood.
I erected a 4x8 table, with sawhorses and planks. Then I glued 4"s of styrofoam on top. The styrofoam let me completely support the lofted luaun and saw out the lines. Once a particular line was cut and sanded, I laid a sheet of 1/2" ply down on the table. I positioned the pattern so as to get the keel, floor, one leg of the hull and part of the deck, as close to the edge of the plywood as possible. I marked the cut, cut it, then scribed the inside line for the frame and cut it. Then I flopped the partial frame over, and used it as the pattern for the other side. Filler strips made up the remainder of the deck beams. Some of the larger frames required seperate sheets for the main frame sections, but the leftovers were used for the smaller frames.
The process was repeated for each frame. There was very little scrap left when I was done.

Even with a space 11x30 to work in, I could only work on one frame at a time. Each frame was laid on the floor over pieces of polyethelene. I mixed epoxy and Cabosil to the consistency of mayonaise and coated all the pieces. When they were properly arranged on top of each other, I screwed them together and into the floor.

Finally, more space to build. On to [990605garage120x90.jpg] "The Graving Dock"

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Copywrite © Alan "Maddog!" MacBride 1999
Most recent Revision 12/18/99