Wa'apa Build - Part 38 (leeboard and rudder part 2)

Continuing leeboard and rudder construction...

The foil template used for shaping the boards

I cut the blank into pieces for rudder and leeboard so I could work on each individually...easier.

Lots of planing and sanding carefully to get to shape...

All shaped it gets a layer of glass for strength...then repeat for the rudder

In between glassing and fill coats of epoxy work on the aluminum plate which attaches to outside of leeboard.

Leeboard attaches to hull with a 1/2 inch / 12mm bolt. I used a 1 inch bit to drill the hole oversized first.

Sealed one side with packing tape..

And poured in some lightly thickened epoxy. When cured I scrape/sand it flush, then drill the 1/2 inch / 12mm hole through that. This keeps the wood safe from wear and water ingress..

Boards after fill coats of epoxy..awaiting sanding and several coats of spar urethane..or paint.

Also received my rudder pintles/gudgeons...

Along with lots of line and other hardware I've been collecting to get the boat rigged....

That's about it for now...to be continued....

Wa'apa Build - Part 37 (leeboard and rudder part 1)

The last big piece of the construction puzzle...the leeboard and rudder. I'm using the foil shape that Michael Storer specifies on his boats which requires me to create a very large blank exactly 22mm thick for shaping. With only my circular saw jig for ripping and hand planes for the dimensioning...I've been somewhat dreading this task knowing it will be a lot of labor and needs to be accurate. 

Luckily it seems I have gotten fairly good at dimensioning stock with hand tools, having done a fair amount of it now. Certainly saves a trip to the gym...

First step, prep the boards. Planing them smooth, mostly removing machine marks for good gluing surface.

And then ripping them all down to this. I need 22mm final thickness, but ripped staves to 30mm to give myself lots of wiggle room just in case things don't go smoothly at first. After arranging the staves how I thought best, was glued up to form the blank.

Once glue is cured out come the hand planes.

One face flattened, edges jointed, marking my 22mm thickness.

Then lots of work with and the hand planes and several piles of shavings later..

And all finished up at 22mm. A major workout but it worked out perfectly without any drama. Just keep the planes sharp and try to remember you (mostly) enjoy this..and at least you won't need a gym membership anytime soon!

Work space cleanup and a new workbench..

Not strictly boat related..but necessary..

After several months of boat construction my home work space (my small porch/patio) was an absolute disaster area and time for a major cleanup. Several hours of major cleanup and organization got things looking respectable again.

Next up was attacking the issue of not having a proper work bench to work on so I could attack the next major piece of boat construction. So I took a break from the boat for a while and built this...

Big, heavy, flat, and very sturdy....makes life so much easier!

Wa'apa Build - Part 36 (spars & mast continued)

Ok..so a whole new year now and a long long time since an update here. Work has continued slowly when possible, but been lazy to update the blog...so here comes several posts to catch up...

Left off with mast staves being scarfed so...

With mast staves scarfed..taper was marked on the narrow ones

And planed down

Large plug for bottom of mast was constructed

And glued to narrow staves then cleaned up

Spacer blocks were fit and glued in

Using center line along wide stave to help align and keep things straight.

Then the wide staves glue on to close it up

All glued up in the rough...

Many shavings later mast cleaned up and looking better

Edges rounded over and bottom section of mast gets a wrap of fiberglass reinforcment. Spars and mast tip also receive wrap of glass on ends to prevent splitting.

Holes drilled into spar ends for attaching the sail, and pad eye fitted to top of mast for the halyard

Then several coats of epoxy to seal up and fill weaves and mast and spars are complete...awaiting sanding and several coats of spar urethane.