Construction Log
"If I had it to do over again . . ."
Here are a few things that I have learned so far in the process of building a boat that I would do differently if I were beginning my project over again:
 
If I had it to do over again . . .
 
a.  I would NOT encapsulate the major hull pieces before assembly.  I have wasted A LOT of epoxy encapsulating and then re-encapsulating after adding structural parts, fillets, etc.
 
b.  I would put my construction stand on wheels so I could move the hull around more easily.
 
c.  I would buy my plywood from a marine plywood dealer FIRST.  Even with the shipping charges, the total cost was about the same price as my local lumberyard would have charged, and I would have been able to begin construction about four weeks earlier.
 
d.  I would take a lot more care when making my early putty fillets.  Sloppy work led to a great deal of VERY BORING sanding.
 
e.  I would arrange in advance for friends to come and help me with moving the hull, lifting, turning, etc.  My wife and I did everything except lifting the inverted hull onto the sawhorses.  When I realized that we couldn't do that ourselves, I finally broke down and asked for "a couple of guys" at church to come and help.  A "couple of guys" turned into about six men, two women, and a toddler!  One friend from church even took photos.  What I learned is that people are interested in a project like this, and are more than willing to help.  You'll be surprised!  I was, and I shouldn't have been; friends like to help!
 
f.  I would be much more careful when applying fiberglas tapes to the exterior.  I allowed A LOT of resin to drip down the sides of the inverted hull, and now I have A LOT of difficult sanding to do!
 
 
Things I did right the first time:
I bought Glen-L's construction video (fortunately, one is available for this design).  As they say, "a picture is worth a thousand words," and the video cleared up a lot of things that I didn't understand in the instructions.
 
I have tried to work on my project for at least a while every day.  Of course, there have been a few "skips," but it has worked out well overall.  Moving to our new home and my Winter hiatus have proved to me the wisdom of this; taking a long break from construction makes it difficult to get going again.  Newton was right!  Inertia is a powerful force!
 
I purchased Glen-L's frame kit.  It saved a great deal of time and anxiety early in the construction process.
 
 
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Progress Report
 
March 16, 1999:  Ordered plans!  The project has begun!
 
March 24, 1999:  Our local lumber supplier is searching for the marine grade plywood I will need.  Also, I've ordered a frame kit and other needed supplies from Glen-L.  I'm now committed!  It's time to build this thing!
 
March 27, 1999:  Now I'm REALLY committed! Today, I purchased our engine--a 1994 40 h.p. Mercury outboard.  Also, the plywood has now been ordered.  It should arrive about the same time as my frame kit (about two weeks).
 
April 10, 1999:  While I'm waiting for my plywood to arrive, I'm in the process of collecting needed equipment and tools.  Today, I purchased two 6 gallon fuel tanks.  Recently, maintenance/operation manuals for my engine arrived and are being studied.
 
April 15, 1999:  I'm still waiting for plywood!  In the meantime, though, I have completed an online safe boating course, and highly recommend it!   I  received a 98% on the final exam.  (Click on the "safe boating" link on the links page for more information.)
 
April 23, 1999:  It's difficult for local lumberyards (especially in the middle of midwestern farm country) to obtain marine plywood, so I've decided to re-order my plywood from an online supplier.  I'm hoping to have it in about a week or so.
 
April 26, 1999:  My frame kit from Glen-L arrived today--a day early and in good order. At least I now have some genuine wooden parts to look at!  The Glen-L folks really do a great job.
 
April 27, 1999:  Speaking of Glen-L doing a great job, my safety and application kits arrived today.
 
May 3, 1999:  MY PLYWOOD ARRIVED TODAY!!!!!!!!!!!!!!!!!! (A big, "Thank you," to Rare Earth Hardwoods!)  I made my first cut in my first plywood panel.
 
May 9, 1999:  My first week of actual construction has gone well.  I have all the hull pieces cut out, and am in the process of joining forward and aft hull panels with butt blocks.  My epoxy seems to be curing, and seems to be holding!
 
May 15, 1999:  I have a hull!  Beginning at 7:20 a.m., and finishing at 12:15 p.m., two large sheets of cut-out and glued-together plywood were folded and stitched into something that actually looks like a boat!   Glen-L makes stitch-n-glue boatbuilding look so easy, and it truly is!  A person like me, with almost no prior woodworking experience, really can build a plywood boat.   Try it!  You'll like it!
 
Stitch and glue:  It's as easy as . . .
 
   1.
 
The hull halves laid out for stitching, and the temporary form installed.
 

2.
 
The two halves are stitched from stern to bow, seen from two angles.
 
3.
The stitched hull ready to be returned to the building shed!
 
Subsequent construction . . .
 
May 23, 1999:  This week, I installed the transom and motorboard, and made my first epoxy putty filets where the main hull plywood panels join.  I've also started to install the plywood keel sections.
 
May 30th, 1999:  The keel, battens and transom knee have been installed, and the long beams are being cut out and assembled.
 
June 6, 1999:  Long beam construction has continued, and they should be installed tomorrow.  I'm waiting for wood, which has slowed things down a little.  I did some sanding, and cut out a few pieces to keep myself occupied.
 
June 13, 1999:  I took my vacation week from work and got quite a bit done (almost 29 hours' worth).  The long beams are installed, I've cut out and assembled the aft and partial bulkheads, and the keel upright.  My mahogany arrived right at the perfect moment, and the inner sheers and breasthook have been installed.  Some of the inner seams have been fiberglassed.
 
June 20, 1999:  I didn't get as much done this week; there's a lot of sanding at this stage, and a little of that goes a long way!  Anyway, fiberglassing of the interior seams, transom and long beams is finally completed, and the partial bulkhead and keel upright have been installed.
 
June 28, 1999:  The forward crossbeams and strongback have been created and attached, and the aft sole cut out.   I've also laid out the interior to get an idea of what the arrangement will look like.   I have purchased my trailer.
 
July 4, 1999:  A VERY slow week--only about three and a half hours.  I made some fillets and fiberglassed them.
 
July 11, 1999:  A VERY productive week!  All under-flat/sole areas received their final coat of epoxy.  All the under-sole electrical wiring has been completed, and the forward flats and the forward section of the sole have been installed.
 
July 18,  1999:  The aft sole pieces and forward bulkhead are installed.  Putty fillets and fiberglassing of sole joints is is proceeding.
 
July 25, 1999:  The forward bulkhead and deck have been installed, and the hull has been turned over for exterior preparation and fiberglassing.
 
August 15, 1999:  My father died three weeks ago, and responsibilities surrounding this loss have kept me away from my project, but now I am beginning to work on it again.  I am continuing with preparing the exterior of the hull for fiberglassing.
 
August 29, 1999:  I am adding the first  bi-axial tapes on the exterior seams.
 
September 6, 1999:  The exterior seams are still being taped in preparation for final fiberglass covering.
 
October 23, 1999:  We're buying our own home in a new hometown, and this, combined with the onset of colder weather here in West Central Illinois, has put my construction on "hold" until Spring!
 
February 27, 2000:  Early warm temperatures have thawed out my enthusiasm for my project.  The partially completed hull was used for storing stuff  when we moved, but now it has been cleaned out.  I've also done some design work on my console.
 
March 5, 2000:  I've cut out two sections of my console.
 
March 12, 2000:  I worked a lot on my console, and like the way it is shaping up.  Because I still have to fiberglass the bottom of the hull, I'm not going to actually install the console sections at this time, although I will install the box pedestals that the two bucket seats will be mounted on.  By the way, I have obtained my seats and a battery.  I purchased the battery now because it is going to be installed underneath the port seat, and I wanted to make sure I make the pedestal tall enough.
 
March 20, 2000:  I'm continuing to work on my seat pedestal boxes.  The weather has not been very cooperative, returning to more "seasonable" temperatures after our earlier stretch of warm days.  Yesterday was the first anniversary of the arrival of my plans.
 
March 26, 2000:  Patience is a virtue that I need to work a lot harder toward achieving; I went ahead and installed my console this week.  It will probably make things a bit more difficult later, but I just had to see how it was going to turn out.  I've continued to work on my seat pedestal boxes as well.
 
April 2, 2000:  The seat pedestal boxes are just about finished (except for the tops).
 
April 9, 2000:  Mostly "cosmetic" sanding this week on the console and seat pedestal boxes.  I also cut and installed a 2x2 cross member athwart ship behind the main seats which will not only give me something solid to strap the portable fuel tanks to, but will also create a "pan" which will keep any accidentally-spilled fuel from going overboard before it can be cleaned up.
 
April 16, 2000:  I put in over seven hours this week, with LOTS of sanding, but also installing the last of my biaxial fiberglass tapes on the interior seams, and cutting my instrument panel for main steering system components.
 
April 23, 2000:  More sanding and puttying interior seams.  I had my first epoxy "failure"--a batch that I used to attach a biaxial tape never really cured.  I ended up having to sand it off and start over.
 
May 14, 2000:  Lots of sanding, and the replacement of the tapes that didn't cure.  One encouraging thing about the sanding is that I realize that some of it is the last sanding I'll have to do on the interior.  There's light at the end of the tunnel!
 
May 30, 2000:  Still sanding!  Yesterday (Memorial Day), we went over to the Mississippi to look for a good place to launch when the time comes, and seeing all the boaters on the river really boosted my resolve to get my boat in the water as soon as possible.
 
April 15, 2001:  Almost a year has passed since I last worked on the boat.  I'm trying to "get going" on it now.
 
July 4, 2001:  I've done some sanding on the hull exterior, and have rearranged my garage so I can turn the hull over to finish the bottom.
 
September 9, 2001:  I'm still sanding the hull exterior, but I'm almost finished.  I should be applying the fiberglass within the next week!
 
September 16, 2001:  And fiberglass I did!  The actual covering of the hull went at least as well, if not better, than I expected, and I'm generally pleased with the results.  The Glen-L construction video was invaluable at this step.
 
November 5, 2001:  I haven't made any entries lately, but that doesn't mean that I haven't been making progress.  On the contrary!, I have finished the fiberglassing of the hull exterior, and have even painted it!
 
February 22, 2002:  Even though it has been a while since I last posted an update, I've been making a great deal of progress indeed.  I purchased a propane space heater for my garage which has permitted me to continue construction even during these winter months.  The engine is now attached and hooked up, and the main seats are permanentnly installed.  The electrical system is on board and operating.  "Finish" work is continuing.  She is just about ready to go in the water!
 
 
April 10, 2002:
First engine test.
She runs! . . .
 
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