Ultrasimple BOATBU I L DIN G 17 PLYWOOD BOATS ANYONE CAN BUILD Gavin Atkin International Marine / McGraw-Hill Camden, Maine (cid:127) New York (cid:127) Chicago (cid:127) San Francisco (cid:127) Lisbon (cid:127) London (cid:127) Madrid (cid:127) Mexico City Milan (cid:127) New Delhi (cid:127) San Juan (cid:127) Seoul (cid:127) Singapore (cid:127) Sydney (cid:127) Toronto Copyright © 2008 by International Marine. All rights reserved. Manufactured in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher. 0-07-159387-X The material in this eBook also appears in the print version of this title: 0-07-147792-6. All trademarks are trademarks of their respective owners. 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DOI: 10.1036/0071477926 Professional D E D I C AT I O N To all the boatbuilders who have done me the great honor of building my boats; and to my mother Copyright © 2008 by International Marine. Click here for terms of use. For more information about this title, click here C O N T E N T S ACKNOWLEDGMENTS . . . . . . . . . . . . . . . .VI INTRODUCTION THE VIRTUES OF SMALL AND SIMPLE BOATS . . . . . . . . . . . . . . .1 PART ONE How to Build Them 1 THREE SIMPLE METHODS . . . . . . . . . . . . .8 4 BUILDING THE HULL . . . . . . . . . . . . . . . .36 THE SIMPLIFIED CHINE LOG METHOD . . . . . . . . . . . . . . . . . . . .8 SIMPLIFIED CHINE LOG METHOD . . . . . . . . . . . . . . . . . . . . . . .36 TWO STITCH-AND-GLUE METHODS . . . . . . . . . . . . . . . . . . . . .9 STITCH-AND-GLUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 COVERING THE HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 2 MATERIALS AND TOOLS . . . . . . . . . . . . .12 ADDING A SKEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 PLYWOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 INWALES, GUNWALES, BREASTHOOKS, LUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 AND QUARTER KNEES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 5 FINISHING YOUR BOAT . . . . . . . . . . . . . .57 FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 PAINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 PAINT AND VARNISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 VARNISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 6 FITTING OUT FOR ROWING 3 BASIC SKILLS . . . . . . . . . . . . . . . . . . . . . .22 AND SAIL . . . . . . . . . . . . . . . . . . . . . . . . . . .62 WORKING WITH LUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 WORKING WITH PLYWOOD . . . . . . . . . . . . . . . . . . . . . . . . . .25 PADDLING AND ROWING GEAR . . . . . . . . . . . . . . . . . . . . . . .63 USING FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 SAILING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 WORKING WITH CHISELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 7 MAKING MODELS . . . . . . . . . . . . . . . . . .77 iv WORKING WITH GLUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 PART TWO The Boats MINIMOUSE AND MICROMOUSE . . . . . . . .84 PUDDLE DUCK RACER . . . . . . . . . . . . . . . .176 HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 SUMMER BREEZE . . . . . . . . . . . . . . . . . . . .184 DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 DETAILS FOR THE SIMPLIFIED CHINE LOG METHOD . . . . . . . .189 SKEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 USING STITCH-AND-GLUE . . . . . . . . . . . . . . . . . . . . . . . . . . .192 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 FINISHING THE HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192 LILYPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 ROWING ACCOUTREMENTS . . . . . . . . . . . . . . . . . . . . . . . . .194 MOUSE AND ROWING MOUSE . . . . . . . . .103 SAILING RIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195 A MOUSE FOR ROWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 DORIS THE DORY . . . . . . . . . . . . . . . . . . .197 CRUISING MOUSE . . . . . . . . . . . . . . . . . . .111 WHAT SHALL WE BUILD NEXT? . . . . . . . .209 POORBOY . . . . . . . . . . . . . . . . . . . . . . . . .116 P H IL B O L G ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 JIM MICHALAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212 DOGSBODY . . . . . . . . . . . . . . . . . . . . . . . .121 MURRAY ISLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 JIGGITY . . . . . . . . . . . . . . . . . . . . . . . . . . .130 JOHN WELSFORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 AURETTE . . . . . . . . . . . . . . . . . . . . . . . . . .137 JACQUES MERTENS-GOOSENS . . . . . . . . . . . . . . . . . . . . . . . .222 CONRAD NATZIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 PIRAGUA . . . . . . . . . . . . . . . . . . . . . . . . . .143 APPENDIX: SUPPLIERS OF BOATBUILDING CINDERELLA . . . . . . . . . . . . . . . . . . . . . . .146 MATERIALS . . . . . . . . . . . . . . . . . . . . . . . .228 FLYING MOUSE . . . . . . . . . . . . . . . . . . . . .154 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 v EEK! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 A C K N OW L E D G M E N T S Huge thanks to my editor at International of the Yahoogroup Mouseboats for their won- Marine, Bob Holtzman, and my friends derful support and interest; to Jim and Eileen Chuck Leinweber and John Welsford for help, Van den Bos, Rosalind Riley, and Tim Bull for ideas, and encouragement; to Ed Bachmann letting me use their lakes; and to my family for for his help with visuals; to those many their tolerance, and especially to Julie for pro- builders of my boats who were kind enough to viding essential life support without which let me use their photographs; to the members this book would never have been written. vi Copyright © 2008 by International Marine. Click here for terms of use. I N T R O D U C T I O N T H E V I R T U E S O F S M A L L A N D S I M P L E B O A T S Iadore secondhand bookshops—the smell, if they were children unable to build a the atmosphere, and the low prices. In my proper small boat. time, I’ve found lots of great books about In contrast, this book is meant to make building small boats on their dusty shelves. you feel confident about building small Because many aspects of boating remain the boats. It will explain how to make the proj- same over generations and even centuries, ect go as smoothly and efficiently as possi- older books on the subject can often be as ble, bearing in mind that mistakes aren’t the relevant today as newer editions, and there’s end of the world. You can correct many with much indeed to learn from them. the help of good old cousin Poly Urethane, However, I have come to dislike certain Uncle Epoxy, and Auntie Filler, so there’s no types of older books, particularly the ones on need to fear potential blunders along the boat carpentry that are more discouraging way. Thankfully, the bad old boat-chopping than helpful. They usually start with an and boat-burning days are long gone. anecdote about how the author tried build- The methods I’m presenting here are ing a boat at a young age and failed. In some tried, tested, and known to work. Over the versions, the author’s father, in a fit of mis- years I’ve noticed beginners often wonder placed and misguided rage, destroys the orig- whether alternative cheaper materials and inal boat with an ax because it’s both shame- methods might work just as well as the ones ful and unsafe; in others he burns it. Usually I have included in this book. The answer is the experience leaves the fledgling boat- some will, some won’t, and some will only builder in tears but determined to win the to a point. If you have a slightly wacky idea father’s approval. Stories like this make me about building a boat from expanded foam angry because when I see them I know it’s or using water-resistant (rather than water- more than likely that the author, deliberately proof) glue, ask about it on the Internet dis- or not, is replaying the part of the angry cussion groups. Someone will almost certainly 1 father and making readers feel inadequate, as have tried the same thing and will be only Copyright © 2008 by International Marine. Click here for terms of use. INTRODUCTION too happy to give you the benefit of his or Being close to the elements can clear a her experience. tiring, stressful week out of a tired brain This book is based on the principle that in a matter of minutes. boating is fun, and that the fun can be ■ Another advantage of being so close to enhanced if we don’t make it too expensive, the elements is that it hones your boat- too much like hard work, or too serious. On ing skills. In sailing, sitting just inches all these points, simple and small home-built from the water in a boat light enough to boats are often the best way to go, and that’s react to every ripple and puff of wind what my own boating journey has been all forces you to react quickly. Even slight about. changes in conditions will require you to Let me explain some of the advantages make adjustments regarding crew place- of small boats: ment and boat balance, sail trim, helm, ■ Small home-built boats have low costs in or oar or paddle strokes. The same is every way, and they are also environmen- true even when you’re steering an out- tally friendly. Building them consumes board motor. small amounts of precious wood and ■ Most children enjoy being captain of small amounts of hydrocarbons in glues their own ship far more than watching and paints. If powered by engines, they their parents have all the fun. Kids who use far less fuel than larger, faster craft have done any amount of summer and put far fewer pollutants into the air. boating will readily say that falling in the They also don’t require antifouling paint water with a crowd of other kids is the because you typically haul them out after funniest and most popular part of the each use, and so they don’t release toxins experience, and that’s only possible in from the paint into the water. the smallest of boats. Introduce them to ■ Handling a small boat is easier and takes small boats at an age as early as six years much less hard work than a big boat. old (with proper oversight, of course) Small boats require less strength to and let them play with friends in their manage and, if you’re sailing, the lines own tiny craft. Almost certainly they’ll are shorter and easier to manipulate. quickly come to love boating on their One person can often launch and haul own and with you. the boat or even transport it on the roof I mentioned my own boating journey, of a car. Novices frequently feel more and I should explain where it has taken me. I comfortable gaining experience on a did a small amount of sailing as a boy and small boat since the forces involved in even built one of the famous Mirror stitch- sailing it are much more manageable. and-glue dinghies with my father. My father ■ Building a small plywood boat is easy, was often busy and stressed, and as a young- quick, and satisfying, and owning and ster it felt good to have a joint project with maintaining it is has less of a financial him. More than that, though, by the time impact on other family members than the boat was completed, I was pretty sure I’d buying and owning a large boat. This is acquired a lifelong interest in small boats an important point: if a small boat has and would be quite confident about building less of an impact on family life in terms one if ever I felt inspired. Sadly, the Mirror of money and time spent on mainte- got very little use. We lived a good distance nance, it is much less likely to cause from any body of water ideal for sailing and domestic strife. my father hated driving. Alas, boating ■ On the fun side, in a small boat you’re slipped below my horizons, and for years I in such close touch with the water you concentrated on traditional music, dancing, 2 feel each puff of wind and every ripple. and hiking for entertainment.