Jim Cav's Passagemaker thread

[Jim Cav]

Thanks Doug. I'd like to accept this nomination on behalf of all the little boats of the world.

I did consider using a V groove bit similar to what's found here:
http://www.rockler.com/product.cfm?page=2122

but that would mean spending money that needs to go towards the varnish and paint for my PMD.

With a router you would want to make several passes instead of ploughing out a ton of wood all at once. You could sneak up
on the final cut and make it really sweet - just touching the corners of the blank.

Clamps? I plan to use duct tape or maybe wire ties...or both. And I'm going to use spruce. While you can use 2x framing timber, I'm
going to a (relatively) local lumber yard that has in INCREDIBLE assortment of woods. Check out their selection:
http://www.downesandreader.com/Products/index.html

I'm heading over there Saturday morning with my brother. I plan on picking up some spruce and some exotic woods for general woodworking projects, and maybe
to incorporate a few accents in my PMD.
This is why I love boatbuilding so much. It incorporates 2 of my favorite things in life...woodworking and sailing.

I'll take more pictures of the setup and processing when I start on the real mast. At 11 feet 3 inches, it's a bit longer than my 8 inch prototype.


Jim

[Jim Cav]

I bought a couple of Douglas Fir 2x4's yesterday and built a mast for my PMD today...the epoxy is still drying.
I took pictures of the process and will either post them here or start a new topic called "Build your own wooden mast".
Let's see how it looks after the epoxy is dry before I get too cocky. Who knows?....I might be starting a topic called "How NOT to
build your own wooden mast"

[Jim Cav]

I checked the mast before coming to work this morning, and I'm happy to report that it looks good.
Granted, I haven't started the finish work which will remove a lot of wood, but it's currently much stronger and
stiffer than the aluminum mast. It took a fair amount of pressure to get it to flex half as much as the aluminum mast did with
relatively low downward pressure.
If I manage to get some free time tonight I'll start the rounding work with the hand plane.

[Jim Cav]

I spent about an hour with my random orbit sander and have my mast looking pretty good. It's still about 1.75 inches for the diameter, and I'd like to get it down
a bit further so I don't have to modify the jaws of the boom or gunter arm. I guess I'll spend some more time with the sandpaper...

[Jim Cav]

I know...I haven't posted the pictures yet...but I'll get there...

I spent a few more hours sanding the mast over the past few days. I came up with a nice system for this.
I drilled a 5/8 inch hole in each sawhorse and inserted a 5/8 inch dowel that sticks out about 6 inches. I then
slipped the ends of the mast over the dowels and voila!..the mast is suspended and better yet..it turns!!
I clamped a bar clamp onto the mast to keep it from spinning, then I took a used belt from my belt sander (50 grit)
and cut it. I now have an 18 inch piece of very heavy-duty sandpaper. I attached a spring clamp to each end to use
as handles, draped it over the mast and proceeded to finish the rounding over. A quick quarter turn (resetting the clamp)
and on it went. It's still about 3/16ths too wide, but I stil have some more sanding to do.
I'm extremely happy with the results so far.

Jim

[Jim Cav]

Okay, as promised, here are some pictures of my mast building adventure.
This isn't everything. I'll save the BIG POST for a new topic once I'm happy with the finished product.

The setup and ripping 1/2 inch strips from the 2x4 doug fir. The hold-down and feather board are critical for controlling a 12 foot board.



After further ripping the strips from above into 1/2 inch by 3/4 inch strips, I cut the "V" groove in one of the 1/2 inch wide sides.
The blade is set at 45 degrees. You make one pass, flip the stave end-over-end, keeping the same face on the table, and complete the groove.




The staves all ready for assembly




All of the staves assembled, glued and "clamped". The aluminum mast is to help keep things straight.




A jack plane makes quick work of knocking off the edges



A belt from a belt sander, works great at rounding everything over. The spring clamps allow for a good grip. You just pretend you're shining shoes.

[Jim Cav]

So what do you do when you don't have a 12 foot lathe? Improvise!

http://www.youtube.com/watch?v=TsD1Tz06-9U

Hey...I survived it...so far...

[GORP]

Very impressive!!! I was thinking of building a carbon fiber mast - but this looks like more fun, and certainly more in keeping with the boat.

[Jim Cav]

Yeah, since it's a wooden boat I wanted to keep it as traditional as possible. I couldn't stand the thought of a metal
mast on her. And a wooden mast isn't expensive if you make it yourself. The 12 foot 2x4 Doug Fir was $33.
It's the labor that adds the cost, but if you're making the mast for youreslf you don't have to include that cost.
The only other costs are a few ounces of epoxy and the varnish to finish it.
I'm also going to make my own wooden mast hoops to attach the sail. And from many posts ago, most folks know
I'm tossing the plastic cleats and using wooden ones that I make myself.
FUN FUN FUN!!!! I love boatbuilding!

[Jim Cav]

I went down to Falmouth on Cape Cod this past weekend and happened upon the Boatbuilders Show in Hyanis. It
was presented by the Cape Cod Marine Trades Association - An organization of over 100 marine-related businesses.
There were a lot of businesses there that build cat boats. My favorite was the Beetlecat. I even bought a couple of their t-shirts.
This link gives more info for anyone interested: http://www.boatcapecod.org/news/blog.pl?id=11

Here are some pictures I took at the show - somehow I managed to forget to take any pictures of the Beetlecat...DOH!






This "TMC Skiff" was really nice.



The Haven 12 1/2 was awesome too!!




A plywood dory.

[Jim Cav]

I'm taking the "Varnishing Techniques for Traditional Boats" this Saturday at Mystic Seaport. I'm bringing a piece of a damaged panel to
experiment on. It'll be interesting to see what this guy recommends for prep and application. I'll pass along whatever I learn.

BTW - I did give my boat a final over-all sanding with 220 grit paper. I used discs made by Norton this time and the difference is significant!
I was able to sand the entire exterior hull with a single disc, and I did NOT have to clean it even once!! The discs I was using before are red,
and after 30 seconds of sanding they would clog up and turn pure white. The Norton discs are yellow, and after the sanding session was done the
disc was still yellow. I do have a picture that shows the used disc next to a brand new one, but I'm unable to upload the image to my web site
at the moment.
Bottom line is that I love these Norton sanding discs! They are long lasting and don't load up with epoxy.

Now...where did that warm weather go? We might get some snow overnight tonight.....yuck.

Oh yeah...I don't think I mentioned it yet...but I have yet another addition to my list of "next boats".
The Melonseed Skiff. I saw one at the New England Boat show and fell in love with the design.

Jim

[drpaddle]

Agreed on both counts! There's a boat builder in Gig Harbor that specializes in lapstrake Melonseeds ... very sweet-looking design. I want one too. Guess I have to finish the PMD first ...

And I've had the same experience with the Norton sanding disks. I kept wondering if I was doing something wrong because the disk kept working.

Any further work on the mast?

[Jim Cav]

Work has been crazy lately, so I haven't had much time for surfing the web or boat building.

I did just place an order with Jamestown Distributors for the finishing products for my PMD though.
Varnish, primer, paint, etc..etc..etc.. I can't wait for the stuff to get here so I can get this boat done!!

I still owe some notes on mast construction and also the varnishing class I took at Mystic Seaport. Soon...soon...I hope...

Jim

[Jim Cav]

I received most of my order from Jamestown Distributors. The white primer and green paint are
backordered, but that gives me more time to spend on the varnish. With a little luck I'll get started
on it tomorrow.

[Jim Cav]

Varnishing requires a warm, dry, calm day. That's something we've been lacking for the past 2 weeks here in New England, so
I have not yet started the finish work on my PMD.

Still waiting patiently......

Jim