M. R. Mittleman, Constructor Member, Long Island Woodworkers

M. R. Mittleman, Constructor Member, Long Island Woodworkers

You wanna do what??? February 24, 2016 Long Island Woodworkers Presentation 2

Some particulars about the craft to be constructed: Model name is Wood Duck Hybrid 12 Designed and marketed by Chesapeake Light Craft Length: 12 0 Beam: 30 Cockpit Size: 38 X 20 Hull Weight: 40 lbs. Max Payload: 350 lbs. Paddler Weight: 80 250 lbs. Knee Height: 13 Max Men s Shoe Size: 14 February 24, 2016 Long Island Woodworkers Presentation 3

What is a hybrid kayak? Wooden kayaks are generally constructed in 1 of 3 ways: Skin-on-Frame A lightweight wooden frame is covered with canvas, Dacron or other material. These craft weigh about 25 lbs. Least weight. Stripping Wood strips, often cedar, are joined over MDF forms. Epoxy and fiberglass are applied to strengthen the construction. Weight is 40 65 lbs. Best looking; longest build. Stitch & Glue Select marine plywood panels are joined over MDF forms using copper wire as thread. Epoxy and fiberglass are applied to strengthen the construction. Weight is 40 65 lbs. Fastest build. February 24, 2016 Long Island Woodworkers Presentation 4

Hybrid kayaks combine stitch & glue and stripping techniques. The hull is built using marine plywood panels joined by copper wire, epoxy and fiberglass. This is the stitch & glue component. The deck is strip-built, often using cedar and/or walnut strips for contrast. February 24, 2016 Long Island Woodworkers Presentation 5

The side and bottom panels are joined by copper wire ( thread ) and shaped using temporary forms February 24, 2016 Long Island Woodworkers Presentation 6

The copper thread and hull forms have been removed. Fiberglass and epoxy have been applied to the inner hull for strength. February 24, 2016 Long Island Woodworkers Presentation 7

The outer hull is fiberglassed and epoxied. The hull is shrinkwrapped to protect the surfaces during the stripping phase. Temporary deck forms are installed. February 24, 2016 Long Island Woodworkers Presentation 8

The first strips are in place. Note the clamping. An axiom: There are never enough clamps. February 24, 2016 Long Island Woodworkers Presentation 9

King plank, coaming apron and first dark strip in place The strips butt the coaming apron. Note the sharp angles that were hand-cut for the strips as well as the curves and twists they must accommodate. February 24, 2016 Long Island Woodworkers Presentation 10

A short discussion about strips Nah, not that kind!!! February 24, 2016 Long Island Woodworkers Presentation 11

Some facts about strips Usually cedar or South American walnut ( Nogal ) Shipped lengths are typically 6 8, however up to 20 millwork can be purchased Thickness is usually ¼, but occasionally 3/16 is available Width is usually ¾, but occasionally ½ is available Light-colored cedar is usually sold as Alaskan Yellow Medium-hued Western Cedar is light brown to reddish February 24, 2016 Long Island Woodworkers Presentation 12

More about strips For jointing purposes, the strips have cove and bead edges, though flat-sided strips are also available The colors and grain are highly variable Photos courtesy of Chesapeake Light Craft and Newfound Woodworks February 24, 2016 Long Island Woodworkers Presentation 13

Even more about strips Problem: The Kayak is 12 (or more), but the strips are 6 8. What to do?!?! Solution: The 8:1 Scarf Joint February 24, 2016 Long Island Woodworkers Presentation 14

8:1 Scarf Joints Typical kayak lengths are 10 20 Purchased and shipped strips are usually 6 8 To attain the required lengths, the strips must be jointed 8:1 scarf joints are used for strength The 8:1 ratio means the joint should be 8 times the width of the strip Strips that are ¾ wide require 8 X ¾ = 6 scarf joints February 24, 2016 Long Island Woodworkers Presentation 15

More on 8:1 scarf joints E-Z Jointing for Long Strips 8ft. Long X 3/4in. Wide X 1/4in. Thick Bead and Cove Strips End View Epoxy thickened with wood flour is used to glue the joints Scarf Joint Cut (8ft. Strip) Cut Approx. 6in. Tape Side View Tape 3/4in. Drying time is 24 hours at room temperature Scarf Joint Cut (8ft. Strip) Tape Tape 3/4in. Approx. 6in. Side View Perfectly Cut Angle February 24, 2016 Long Island Woodworkers Presentation 16

Still more on 8:1 scarf joints Long scarf joint and narrow strips make are challenging to cut, especially with hand tools. Maintaining tight joints until the thickened epoxy dries can also be difficult Two jigs to the rescue!!! February 24, 2016 Long Island Woodworkers Presentation 17

8:1 Scarf Joint Cutting Jig for ¾ Strips Top View 1 Strip Guide Saw Guide ¾ Strip Strip 3" 1 Saw Guide Strip Guide 6" End View Strip Guide Strip Guide February 24, 2016 Long Island Woodworkers Presentation 18

8:1 Scarf Joint Cutting Jig for ¾ Strips Top View; Saw Guides Removed 1 Strip Guide ¾ Strip ~ 6" Cut Strip 3" 1 Strip Guide 6" February 24, 2016 Long Island Woodworkers Presentation 19

Epoxy Glue Jig for ¾ X ¼ Strips Perspective View ½ in. ¾ in. 12 in. 1 ¼ in. 8 in. Materials: 1 pc. 12" X 8" X ¾ plywood 1 pc. 12" X 8" X ½ plywood 5 pcs. 1 ½ X ¼ bolts 5 pcs. wing nuts for ¼ bolts 10 pcs. Flat washers for ¼ bolts Notes: 1. Use countersink for bolt heads and washers. 2. Epoxy bolt heads and washers to the jig bottom. Epoxy washers only for the jig top. 3. Line inside of top and bottom sections with freezer paper before each use to prevent epoxy adherence. February 24, 2016 Long Island Woodworkers Presentation 20

Epoxy Glue Jig for ¾ X ¼ Strips Front View ½ in. ¾ in. 12 in. Bolt + washers + wing nut arrangement 1 ½ in. Washers and bolt heads are countersunk Bolts are 1 ½ X ¼ February 24, 2016 Long Island Woodworkers Presentation 21

Epoxy Glue Jig for ¾ X ¼ Strips Bottom View (Bottom section) 8 in. 12 in. Countersunk 1 ½ X ¼ bolts and washers February 24, 2016 Long Island Woodworkers Presentation 22

Epoxy Glue Jig for ¾ X ¼ Strips Strip 1 Strip 2 Use View (Bottom section) Strip 3 Strip 4 Strip 5 Strip 6 8 in. Strip 7 Strip 8 12 in. = Bolt hole; ¼ dia. February 24, 2016 Long Island Woodworkers Presentation 23

Designing the deck stripping Create a design BEFORE attaching the strips After a few hours of doodling, a final design emerged: February 24, 2016 Long Island Woodworkers Presentation 24

The deck starts to appear February 24, 2016 Long Island Woodworkers Presentation 25

The stripped deck is removed, sanded, epoxied and fiberglassed February 24, 2016 Long Island Woodworkers Presentation 26

Deck temporarily placed on hull and a hatch hole cut February 24, 2016 Long Island Woodworkers Presentation 27

Sometimes problems appear: an 11/16 gap between the bulkhead and deck bottom Solved by adding an arch February 24, 2016 Long Island Woodworkers Presentation 28

Permanently attach the deck and hull, one side at a time February 24, 2016 Long Island Woodworkers Presentation 29

Need to fiberglass the top of the deck February 24, 2016 Long Island Woodworkers Presentation 30

Need to sand between epoxy layers Each fiberglass application required 3 layers of epoxy to achieve a smooth surface by completely filling the weave of the cloth February 24, 2016 Long Island Woodworkers Presentation 31

Attach the coaming February 24, 2016 Long Island Woodworkers Presentation 32

Attach the hatch sill and rim February 24, 2016 Long Island Woodworkers Presentation 33

Add about 10 oz. of epoxy to the bow for strength February 24, 2016 Long Island Woodworkers Presentation 34

Preparing to Paint the Bottom Panels Plastic sheet to protect side panels; 1 st primer coat February 24, 2016 Long Island Woodworkers Presentation 35

Sanding between coats; bottom painted Paint was applied with a 4 foam roller and then tipped (very light strokes) with a 3 foam brush to remove air bubbles and roller tracks. Five coats of polyurethane with light sanding between applications was the technique employed. February 24, 2016 Long Island Woodworkers Presentation 36

Side panels and deck varnished 5 coats of varnish and light sanding (400 grit) between applications February 24, 2016 Long Island Woodworkers Presentation 37

Adding optional equipment: bow and stern pad eyes and toggles February 24, 2016 Long Island Woodworkers Presentation 38

Adding optional equipment: foot braces, deck lines and hatch toggles February 24, 2016 Long Island Woodworkers Presentation 39

Adding optional equipment: comfortable seat February 24, 2016 Long Island Woodworkers Presentation 40

Some useful web sites for plans and kits Company Name URL Notes Bear Mountain Boats http://www.bearmountainboats.com Kits; materials; supplies; plans; books Chesapeake Light Craft http://www.clcboats.com Great site; information; kits; supplies; builders forum; tools Clark Craft http://www.clarkcraft.com Long-time supplier of materials, accessories and kits Guillemot Kayaks http://www.guillemot-kayaks.com Exquisite craftsmanship; kits; plans; accessories; interesting blog Noah s Marine Supplies http://www.noahsmarine.com A complete site; information; kits; tools; accessories Northwoods Canoe Company http://www.wooden-canoes.com Plans; kits; restorations; books and videos Pygmy Boats Inc. http://www.pygmyboats.com A complete site; kits, supplies; information February 24, 2016 Long Island Woodworkers Presentation 41

Some useful web sites for plans and kits Company Name URL Notes Redfish Custom Wooden Kayak & Canoe Company http://www.redfishkayak.com Another great site; information; kayaks and canoes; full-length strips; builders directory Sandy Point Boat Works http://www.sandypointboatworks.com Kits; plans; tools; accessories; information; blog Shearwater Boats http://www.shearwater-boats.com Kits; plans; complete boats The Newfound Woodworks Inc. http://www.newfound.com Gorgeous craft designs; supplies; accessories; tools White Salmon Boat Works https://www.raysdreamboats.com Beautifully designed kits and completed craft; full-length strips; accessories; information February 24, 2016 Long Island Woodworkers Presentation 42

Handy tools and supplies February 24, 2016 Long Island Woodworkers Presentation 43

A few sources for tools and supplies Company Name URL Notes Ace Hardware http://www.acehardware.com Tools; supplies Amazon http://www.amazon.com Great source for tools; hardware; supplies; accessories Garrett Wade Tool Company http://www.garrettwade.com Tools Glen-L Marine Designs http://www.glen-l.com Adhesives; kits; plans; tools; information Harbor Freight Tools http://www.harborfreight.com Tools Home Depot http://www.homedepot.com Tools; supplies Jamestown Distributors http://www.jamestowndistribut ors.com Great source for tools; hardware; supplies; accessories; information Klingspor Abrasives http://klingspor.com/products Tools and supplies, especially abrasives February 24, 2016 Long Island Woodworkers Presentation 44

A few sources for tools and supplies Company Name URL Notes Lie-Nielsen Toolworks, Inc. https://www.lie-nielsen.com Heirloom tools, especially planes Lowe s Home Improvement http://www.lowes.com Tools; supplies MAS Epoxies http://www.masepoxies.com Epoxies; adhesives; supplies Rockler Woodworking and http://www.rockler.com Tools; supplies Hardware Sears http://www.sears.com Tools; supplies System Three Resins http://www.systemthree.com Epoxies, related tools and materials; great information West System http://www.westsystem.com Epoxies, related tools and materials; great information February 24, 2016 Long Island Woodworkers Presentation 45

Mike Mittleman Long Island, New York 40 52 31.7604 N 73 11 3.5700 W mrmittleman@optonline.net February 24, 2016 Long Island Woodworkers Presentation 46