My
Backyard Boats:
The
Quark: Single file
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This
page presents the Quark's building log in a single file; the
log entries are stacked chronologically. For an index of the
individual log entries, click
here.
 
A
good beginning
14
March 03: I went out this morning and got the wood
to build my next boat, the Quark. The pile of lumber and plywood
doesn't look like much, but it will do the job. It felt good
to get going on the boatbuilding season. I got a sheet of bc
pine instead of luaun, which I had assumed would be fine, but
sometimes Home Depot run out of luaun, so I got the pine ply.
I love the way it smells. And it has three equal plies, unlike
the luaun. It is a bit heavier, but that isn't a problem in
a boat this small. I'll build this one in the basement while
waiting for the weather to warm. There is still snow on the
ground, though the weekend is supposed to be in the 50s for
the Ides of March.
Cost
so far: $49.06 for lumber, $25 (I think) for the plans
-- bought about a year ago, and seemingly no longer available
(visit Jim's website to email him if you want plans). I have a
few boards and some epoxy that are left from other projects that
I'll use on this one, but I want to have a fair idea of cost,
too, so we'll say $30 for epoxy and $20 for boards on hand, for
a grand total so far of $124.06.

Quark's
story takes a single sheet of blueprints.
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Detail
of blueprints shows profile, top view, and the way to cut
the sides and bottom from a sheet of 1/4-inch plywood. |
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Detail
of temporary frame, left, and the stem. |
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A
sheet of plywood, a 2x4 9feet, 4 inches long, and a 1x4
pine board for the temporary form don't take up much room
in the truck. |
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Our
house is more than 100 years old, and the steps to the basement
are probably about that old. Someone along the way learned
that a notch in the landing at the mouth of the top of the
basement stairs was needed to persuade a full sheet of plywood
to go on down. |
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Jokes
and puns notwithstanding, I'm eager to build this little
boat. It won't take much more than the plywood and three
boards to make it, either. |
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Sides,
form, transom in the bag
18
March 03: I
got a lot done today on the Quark project -- plywood cut for the
sides, temporary form made, and the transom cut out and beveled.
Next step is to make the stem, then I can put the hull together.
Time
spend so far: 1 hour at the home store, and 5 hours
in the shop today for a total so far of 6 hours.
After
drawing the curve of the sides onto the plywood, I cut
out the pieces, clamped them together with two large wooden
clamps and faired the edges.
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I rented a scuffle floor sander a few years ago and ended
up with a lot of 15-, 20-, and 36-grit sandpaper. This stuff
is wonderful. It cuts like a wood file and lasts forever.
The tool in this pic is simply two pieces of pine screwed
together at a right angle, with 36-grit sandpaper clamped
between. |
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After
using block plane and sandpaper tool, I check for parallel
edges with the tri-square. There will be more fairing to
do after the external chines are attached to these side
pieces. |
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I
took my time with the temporary form so that it would be
accurate. I used a piece of select 1x4 pine to get a good
edge on all sides. The bottom is 22 inches wide, and the
top is 28 inches wide. The form is 12 inches deep. |
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The
transom is in the center of this pic, with a pattern I made
from plywood to its left. Glad I made a pattern, because
the measurements were tricky. Surrounding the transom are
some of the tools that I used on the three steps that I
did today: rafter square, sliding bevel gauge, tri-square,
4-in-1 rasp, power jig saw, and eye protection. |
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Stem
looking good in poplar
19
March 03: I
cut the stem out tonight from a piece of select-grade poplar 2x4
that I had lying around the shop. It looks great, and I like everything
about poplar except the smell, which isn't all that bad but it's
just that I love the way pine smells. Poplar and pine cost about
the same in select grade. This Quark boat project is as much a
test of poplar as anything else, since it really may be too small
for an adult to use. We will see on that. The poplar will get
a test when I rip the pieces for the external chines. I'm seriously
considering using poly glue, the kind that kicks when one board
surface is wet down before applying the glue. Since this boat
is for experiments, I'm going to consider using cheaper glue for
the initial bonding, then use epoxy fillets on the inside and
a coat on the outside, with glass tape on the chine joint.
I
cut the stem out with the table saw, after removing the saw guard
and setting the angle. It was a bit tricky but went well. The
saw guard was not setting right, which made me think that the
saw would actually hit it, so I removed it for the operation.
I don't like table saws and I don't like to work without the guard,
but I don't like living in fear even more, so I did what I did,
carefully.
Time
spend so far: 1 hour at the home store, and 5 hours
in the shop yesterday, and an hour today, for a total so far
of 7 hours.
Stem
wood is pretty in poplar -- 2x4x15 inches.
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I used a pen to line out the cuts. |
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The
finished stem. It is within a 64th of the plan dimensions.
That's pretty good for my table saw. |
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Elmer
rewrites the hull story
21
March 03: I
had two surprises today -- Elmer's new woodworking glue with wood
flour added and the Quark hull looking like its big enough for
an adult.
I
was excited about both of these things.
I
used Elmer's woodworking glue (exterior) and ringed bronze boat
nails to assemble the sides of the hull for the Quark and also
to install the sheer clamps. When I got the sides in place, and
the stem and transom dry-fitted, I noticed that I was off by one-half
inch when I strung a line from stem to stern. After putting on
the sheer clamps, the hull trued up. I used an extra stringer
clamped to the sheer clamp on one side to pull the hull into alignment,
and it worked.
The
next step is to nail the external chines to the sides and then
nail and glue on the bottom.
I
ripped a poplar 2x4 into strips for the clamps and chines. I set
up my cuts so as to have the grain parallel to the sides, which
helped in the bending, and will give more strength than if I had
cut the strips as vertical grain pieces. The poplar is probably
25 percent heavier than pine, and it warped as soon as I cut it,
but for clamps and chine that is actually a plus. I probably could
have driven the boat nails without drilling pilot holes but I
did anyway because I had a nasty split early on when I was dry-fitting
the transom.
Time
spend so far: The total going into today was 7 hours.
Add to that today's 6 hours of work, for a total of 13 hours so
far.
Cost
so far: Going into today the coast was $124.06. Add $3.60
for 8 ounces of the Elmer's glue, for a total so far of $127.66.
The
first step was to attack the temporary form to the sides
with deck screws. |
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Rope
is used to make windlasses to pull the sides together
while the stem and transom are dry-fitted with deck screws.
This is a tricky part of the process; it is important
to pull both ends in; the bevels don't seem right if you
don't. It helps to have a helper, if you like to work
with anyone else around. I don't, so I persevere, and
use rope.
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Form,
stem, and transom in place, held with deck screws. Although
the deck screws are self-tapping, I drilled pilot holes
to avoid splits. |
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To
make sure than the hull isn't twisted, you run a string
from the centerline on the stem to the centerline on the
transom. I like to use a stick upright on the form's centerline,
rather than a plumb bob. The stick doesn't have to be
held; it's always there for reference.
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To
apply glue, back off all the deck screws but one. I used
a throw-away paint brush to apply the glue. |
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One
of the sheer clamps in place. The line indicates that the
hull is way out of alignment; I used an extra clamp on one
side temporarily to put the hull into alignment. It was
a half inch off until I fixed it. |
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At
the end of the day, the hull and sheer clamps were done.
Next step is to nail and glue on the external chine stringers
and the bottom. |
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A
digression on glue for boatbuilding
Water
resistant, one-part, nontoxic, water cleanup, and wood
flour added at the factory to make it stay put in use
-- Elmer's glue. |
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Japanese
saw makes short work of plastic water bottles. I cut
right under the label to make a cup for mixing epoxy.
The ripples in the bottle are my measuring marks. The
method works. When I want to slow down the epoxy on
a hot day, I use plastic tubs sold as storage for leftovers,
but I mix in the cut-down bottles.
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20
March 03:
I would like to be able to use epoxy for all uses in boatbuilding,
but there are several factors that push me in the direction
of finding additional options:
-
Epoxy
at ClarkCraft,
which is a few minutes from my house, on the Niagara River,
costs $55 per gallon plus tax. I like the convenience
of getting this specialty in gallon size without having
to pay shipping charges that could be as much as $10,
and I like the one-to-one mix ratio of resin and catalyst
(I use plastic water bottles that I cut with my Japanese
draw-cut saw to leave a cup-size container
with regular ripples in the sides that I use for measuring).
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Epoxy
has no equal for gap filling and strength; it also has
no equal for toxicity and
messiness, and the possibility of sensitization is always
there. Sometimes I just want to glue two things together
without donning surgical gloves, face mask, long sleeves,
hat, and safety glasses,
then mix and use in a hurry to avoid waste. And then there
is the question of when to stop monitoring for drips and
dribbles and curtains and runs. Often I epoxy at the end
of a long session of work to prepare for gluing, and I
go inside and clean up, only to find the next time I'm
in the shop that the epoxy has made a runny, rockhard
mess on surfaces I will have to sand and sand and sand.
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Small
jobs such as filling a few but crucial screw holes in
the hull of a boat that I'm building require the donning
of all the safety gear and some attention to the amount
to mix and what to do with the excess, if any.
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The
alternatives to epoxy in my mind include poly glues that
call for wetting one of the surfaces to be bonded and
glues such as Titebond II that have water resistance but
not gap-filling qualities. I have used resorcinal, many
years ago, and my father before me used this glue exclusively
in prewar and postwar years of boatbuilding. Resorcinal
leaves a purplish, reddish line at each glue joint, and
it kicks off slowly depending on the temperature. It stains
wood in ways that reduce the beauty of varnished surfaces.
It demands tight joints and heavy clamping. Epoxy, by
contrast, is stronger when there are gaps and bridges
gaps effortlessly; clamping is accomplished with a box
or two of self-tapping deck screws in sizes from 3/4 inch
to 1 inch.
-
Robb
White, a frequent contributor to Messing
About in Boats, wrote an article about
epoxy a few years ago. He says that epoxy will penetrate
joints if there is enough heat. He assembles pieces and
then ups the heat in his shop or uses a heat source such
as a handheld hair dryer to encourage the epoxy to penetrate
joints. Mind you, I am relating this from memory, and
any lapses or distortions of Robb's approach are mine,
not his. I used this approach in the building of my Harmonica
canalboat mainly due to entropy: When the time came to
seal the edges of the plywood I used for the foredeck,
I covered the edges with moulding without any prior coating
with epoxy. When I was finished installing the L-moulding
that I used to edge the deck and provide a toe-rail effect,
I brushed on epoxy on a hot day and made sure that I sealed
the joint between the deck and the moulding, hoping that
there had also been penetration to the plywood edge. I
figured that a fillet-type seal on the moulding would
do the job fairly well, but I also was uneasy about my
choice.
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I understand that strip-built boats can be joined with
fasteners and cheap yellow glue such as Carpenter's Glue
or Titebond II. These glues clean up with water and don't
stain wood, though they will mar a surface if allowed
to lay and cure in drips and rings, because of the differences
in penetration of varnish, and stain (though why you would
ever want to stain a wood on a boat is too many for me
to figure out).
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Epoxy makes fasteners almost redundant after the stuff
has cured. The epoxy is stronger at the glue line that
the surrounding wood is by nature, and the addition of
fasteners is necessary to keep the pieces in reasonable
proximity while applying the epoxy and waiting for curing
to finish. I use bronze ringed boat nails for most of
my fastening needs, and after buying some stainless steel
screws, and using zinc-coated when I didn't have the stainless
sort on hand, I have been trying to avoid screws as much
as possible. I do like the way they look, but I have a
growing confidence in epoxy alone to hold most boat parts
in place.
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After marring the finish of one boat with microballoon-augmented
epoxy, I no longer use microballoon additives. I could
tell any difference anyway. I also don't use Cabosil anymore,
though it is higher in my estimation than microballoons.
I use wood flour if I want to thicken epoxy, and nothing
else. I like its cost and the way it works, and it doesn't
scare me as much as Cabosil does when it gets airborne
while my dusk mask is hanging on the wall instead of in
place on my face.
When
I built The Weekend Skiff,
I was determined, based on promotional materials to which
I am highly susceptible to use the two-coat epoxy sealing
approach on all surfaces. Since then, I have read about boatbuilders
who say that the inside of the boat should be allowed to breathe
some and allow moisture to escape, builders such as my
wife's brother-in-law who even use interior plywood
on boats that they store in the garage between outings, builders
who swear by an interior coating of equal parts of linseed
oil and turpentine (smells wonderful!) applied once a day
for a week, once a week for a month, and once a month for
a year. Another of my brothers-in- law, a builder of fine
homes in California, swears by the principle that all sides
of wood used in construction must be treated in the same manner.
All this is a prelude to my decision
on this latest boat project, the
Quark, to try something new. I am at the point
of putting the hull together and have decided to use a one-part
glue such as Titebond II to glue the parts together with the
aid of ringed boat nails and perhaps deck screws on such parts
as the gunwales and external chines. I will be aiming for
a reasonably close fit but not resorting to clamps. Some gaps
are fine, because I will fill them with thickened epoxy as
a second step, then use epoxy to tape the chine joints and
to seal the outside of the boat.
I have been wanting to test further the idea that the outside
of a boat can be sealed with epoxy, to give abrasion protection,
a good base for paint or varnish, and as a seal against the
penetration of water through the joints; on the inside of
the boat, I want to test the effectiveness of epoxy as a fillet
sealer on joints such as chines and around centerboard cases
and other joints at or below the waterline, with varnish or
paint on the other surfaces, but without a base coat of epoxy.
I like the idea that the boat can breathe and expel moisture
rather than encasing moisture with epoxy on both sides. I
am partly influenced by those who assert that fiberglass boats
are heavier at the end of a season in the water than they
are at the beginning of the season when they are put back
into the water. That tells me that epoxy-saturated fiberglass
does not exclude all moisture, so it is not necessary, and
perhaps not wise, to use the epoxy encapsulation method that
the epoxy manufacturers swear by.
The overriding consideration for me is the fact that I store
my boats inside when not in use, and that the storage is reasonably
dry and weathertight, but not heated. I also am aware that
I live in the northern tier of the country on the Great Lakes,
where there is seldom a prolonged problem with high humidity
and high temperature of the sort that Robb White, say, encounters
in Georgia.
Update: When I went to the home store to
get some glue, I chose Elmer's Carpenter's Wood Glue (Exterior),
which has wood flour added to slow down runs and ripples,
got my vote over the poly glues, because Elmer's doesn't expand
as it dries; the poly glues foam up and expand while drying;
and because Elmer's was half the price of poly glue. Elmer's
is about half as expensive as epoxy; poly glues are as expensive.
Elmer's cleans up with water; poly glue cleans up with mineral
spirits. Elmer's is not toxic; poly glue is a bummer if it
stays on the skin.
Update
from 3-21-03: I loved using the Elmer's instead of
epoxy for putting the hull together on the Quark. This new
kind has wood flour, which makes for zero (!!!!) runs. The
glue stays where you put it, and even when there is some squeeze-out,
the glues stays in place instead of running and rippling.
Set-up time at 60 degrees F. or so was generous, which is
good because often when epoxy is curing, there is still fitting
and re-doing to contend with. The hull is doing fine with
Elmer's and bronze boat nails. Unlike the case with epoxy,
the boat nails are necessary for a backup to the Elmer's.

Will
it float? Yes it will, now
24
March 03: When the kids in the neighborhood walk
by, while I'm building on a boat in my garage, they always
ask, sooner or later, "Will it float?" The Quark
will, now, because the hull is done. Yesterday, I put
on the external chines, and this evening I installed the
bottom piece of plywood with trusty Elmer's glue and boat
nails. The boat is a lot more seaworthy-looking than I
had thought it would be, and I'm looking forward to using
it now that I can see it will accommodate an adult of
my size. The next step is to trim the bottom and soften
(or radius) the chine joint, then apply epoxy tape on
the outside of the chine. Then thickened epoxy on the
interior joints, then two thwarts, and a skeg, and a paint
job. I'm thinking about yellow on the outside and bright
on the inside and the sheer clamps.
Time
spend so far: Add to the 13 hours total to date
2 hours for the chines and 2 hours for the bottom, for
a total so far of 17 hours.
After
the clines were in place, I had a spot on each side
forward of the temporary form where the plywood was
standing 1/2 inch proud. If I had done the stitch-and-glue
approach, this may not have been a problem. However,
with the external chine, which was a fair curve, by
nature, I cut the plywood to match the chine. There
also was a slightly less noticeable proud stretch on
each side aft of the form, which I also faired with
the chine. |
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Chines
are glued and nailed in place, with light clamping
pressure. Love that new Elmer's glue!
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Bottom
piece of plywood nailed and glued in place. There was
not more than 1/2 inch to play with because I used the
external chine option. |
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I'm
thinking that the hull shape is reminiscent of a dory
rather than a kayak. I call this a kayak because I'll
be using double paddles instead of a single -- which
would make this a canoe. I read that somewhere, as
a way to distinguish between canoes and kayaks, by
focusing on the style of paddle used.
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Detail
shot shows sheer clamps and external chines. I milled
the sheer clamps oversize by 1/4 inch and the chines
are under by a 16th. This had to do with monkeying with
a 2x4 and making some slight miscalculations. I'll round
the sheer clamps a lot, but I'm not sorry about the
extra material. Can't hurt. |
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Twice-thwarted
in good form
I
installed the two thwarts in the Quark today, and did some
planing on the excess plywood on the bottom. The only thing
left to install is the skeg; the rest of the work will be
sanding, trimming, and epoxy coating and fiberglass taping.
I still like the look of this little boat, more so because
I didn't expect as much boat as it is.
I
decided to get some good screws for the thwarts, so I went
to West Marine, a few minutes from the house, on the Niagara
River, and got eight brass screws at 40 cents each. I couldn't
touch the stainless steel ones. Still, it was better than
going to the home emporium, though the screws are a lot cheaper
there.
Time
spend so far: Add two hours for the thwarts
and planing today, for a total so far of 19 hours.
Cost
so far: Going into today the coast was $127.66. Add
$3.46 for the eight brass screws, for a total so far of $131.12.
| Telephoto
closeup of brass screw and thwart. The thwarts, of which
there are two, are made of 1x2 poplar. The plans show a
simple butt joint. I opted not to do a fancy curved thwart
of the traditional sort. I may make some kind of seat back
after I try the boat out, though. |
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After
gluing and screwing the thwarts in, I took out the temporary
form. Still haven't shaped the stem where it stands
proud of the hull. The plans show a rounding and the
drilling of a hole for a painter.
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There
is about 1/4 inch of plywood to trim with the block plane
and wood file before rounding for the fiberglass tape. |
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Bonding
stage begins
01
April 04: The
hull is done except for the skeg, so it's bonding time. That's
how I see the hands-on work, which will take at least half of
the total time, to shape and sand the boat into its final form,
with the hands-on work of epoxying and painting thrown in.
It
took three hours to trim the bottom flush with the chines. I
could have done it in a flash with the belt sander, but I wanted
to become more acquainted with the wood, and I wanted to avoid
the sore throat that comes from making a lot of wood dust in
the basement. The bc pine has a hard/soft grain like fir, so
the hand work, done with block plane, large file, and large
rasp, is still uneven and will need to be finished with the
random-orbit sander.
I
went to ClarkCraft
to get a gallon of epoxy, which will be more than enough to
finish this project, and the next, too, I hope. I also picked
up a quart of boiled linseed oil and a quart of turpentine.
Plus more of the Elmer's exterior glue, and a bunch of throw-away
paint brushes (which I actually try to reuse by cleaning them
with acetone).
Time
spend so far:
Add three hours for the trimming of the bottom piece, for a
total so far of 22 hours.
Cost
so far: Going into today the coast was $131.12. Add
$12 for the linseed oil, turpentine, and some of the brushes.
for a total now of $143.12. I''ll add an amount for epoxy when
I see what I end up using.
| After
three hours with the block plane, large file (to deal with
the heads of the boat nails, which are generally close to
the edge of the joint), and the large rasp, I still have
a bit of work to do to even up the joint. The hard/soft
nature of the bc pine makes for a big challenge to the hand
tools. The random-orbit sander will make short work of the
problem. |
|
Detail
of the stem, sides, bottom, and chines, showing a small
gap at the end of the starboard chine that epoxy will
fill nicely. The boat nails ended up close to the edge,
but I was more concerned to avoid punching through.
This makes trimming the edge a longer job, but I'm not
complaining.
|
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Detail
of the bottom-chine joint after the trimming work was
finished. |
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Bring
on the power tools
|
Full-size
version of this pic here.
|
11
April 03: Last
night I moved all my tools and the Quark out to the garage from
the basement. It's finally warm enough (55 degrees F. today)
to work outside. The first thing that I did was use the belt
sander and the random-orbit sander to radius the chine in preparation
for fiberglass tape.
A little girl from down the street who
takes an interest in my boat projects stopped to show a new
friend the funny old man who doesn't care what he is building,
as long as it's a boat. I'm smiling.
Time
spend so far:
Add three hours for using power tools to radius the chine, for
a total so far of 25 hours.

Adventures
in fiberglass tape
15
April 03: It is always an adventure when I apply
fiberglass tape to a chine joint. Puckers, ripples, and runs,
with dribbles and blobs thrown in for variation, are the order
of the day. Last night was no exception, though I felt that
I may someday approach this task with fiberglass tape on curved
surfaces with something an least mocking, if not approaching,
confidence. The holdout is the vertical surface that is tape-covered.
The puckers and inadequate filling of the fiberglass weave
continue to elude my efforts.
That said, I am pleased with the results.
This afternoon I followed up with cutting out and epoxying
on the skeg. (Go here
to see several pix and detailed text about how I did the skeg
for Moby
Dink.) I used a piece of fiberglass tape (I don't
have any problems on level surfaces with the tape) to even
out the skeg joint with the bottom of the boat and to erase
the proud edge of the tape that I applied last night. That
edge was throwing off the skeg joint by almost an eighth of
an inch. I followed up with a fillet along the skeg edges
made with wood flour-thickened epoxy.
Next
task is to turn the boat over and shape the gunwales, thwarts,
stem, and transom to final finish and to decide what, if anything,
to do to the inside joints. I may used a bead of thickened
epoxy to add some strength, since I like this boat and hope
it will serve as a spur-of-the-moment fun thing for years
to come. After these jobs are done, I'll put the first of
many coats of a 50-50 mixture of turpentine and linseed oil
on the interior.
Then
I'll flip the boat again and sand the epoxy, touch up the
fill on the fiberglass tape, and then put on some construction
yellow Interlux Brightside paint I have left over from painting
the trim on the Harmonica.
Time
spend so far:
Add three hours of fiberglass tape work and two hours to install
the skeg, for a total so far of 30 hours.
Cost
so far: Going into today the coast was $143.12 Add
$10 for epoxy and $3 for fiberglass tape, for a total so far
of $156.12.

Bring
on the power tools
11
April 03: Last
night I moved all my tools and the Quark out to the garage
from the basement. It's finally warm enough (55 degrees F.
today) to work outside. The first thing that I did was use
the belt sander to radius the chine in preparation for fiberglass
tape.
A little girl from down the street
who takes an interest in my boat projects stopped to show
a new friend the funny old man who doesn't care what he is
building, as long as it's a boat. I'm smiling.
Time
spend so far:
Add three hours for using power tools to radius the chine,
for a total so far of 25 hours.
Ready
to go on the fiberglass tape application to the chine
joints. Note the glue line of the plywood, which is
your guide to an accurate radiusing of the edge. The
dark dots are what's left of boat nail heads after the
fairing was done. |
|
It's
late, and dark, but the job of taping the chine joints
was done, and well-done, too.
|
|
In
the light of the next day, after the epoxy was finally
set up enough to stop running and rippling, I surveyed
the damage. It wasn't bad. I was more disappointed by
the puckering of the fiberglass tape on the chine, as
shown in the top portion of this pic. I figure that
I'll grind to a smooth surface and reapply epoxy. I'll
be careful to leave the chine jont edge alone, though. |
|
Rough-cut
skeg, made from a piece of clear 1x4 poplar, sits on
fiberglass tape, ready for epoxy filling of the fiberglass
weave and applicatin of a bead of wood-flour thickened
epoxy along the edges of the skeg. |
|
All
done for today. Looks good! |
|

What's
black and white and read all over? My boat is, after
an application of duct tape and old newspapers to define
the edges of the fillets for the inside joints. |
|
The
finished job promises a minimum of sanding.
|
|
Detail
shot shows the fillets on the transom and chines. The
strong line bisecting the transom is the aft thwart. |
|

Seven
more hours of bonding
23
April 03: Still bonding with the boat ... to
the tune of seven hours more of sanding with the random-orbit
sander. I'm almost ready to put on the primer; I still
have to decide what to do about the fiberglass tape
on the chine joints. There are a lot of little craters
where the epoxy failed or something.
My
choices seem to be to put on a second layer of fiberglass
tape, or to grind down the layer in place until the
imperfections (and most of the tape) go away, or to
live with it. I don't intend to put the time and money
into a second layer of tape, and I don't want to lose
the layer that's there, so I will probably just live
with the result so far. When the boat is in the water,
I won't see it, and the bead of epoxy on the inside
will assure a water-tight hull, so live with it it is.
I had intended to use epoxy to putty the holes left
from screwing the sides to the temporary form, but I
decided that the job was too small, so I'm trying 3M
5200 sealant as a putty. It went on fine. I'll need
to put on at least one more coat of the5200, then I'll
prime. While the putty is drying, I'm going to make
the double paddle.
Time
spend so far:
Add seven hours of sanding, for a total so far of 41
hours.
Cost
so far: Add $5 for sand paper, for a total
so far of $166.12.
| Seven
additional hours of sanding has brought the hull close
to the finish that I want. |
|
I'll
be happy if the 3M 5200 compound works as a filler.
It'll take at least one more coat to bring the patches
level. Pic shows the holes left from screwing the
sides to the temporary form.
|
|
Tried
3M 5200 on a spot on the chine to see how it will work
there, too. Pic shows the generally rough condition
of the fiberglass tape on the chines. |
|

Double
paddle without twaddle
25
April 03: Yesterday
and today I worked up the double paddle for the Quark.
The plans call for using 1-inch closet rod for the shaft
and 1/4-inch leftover plywood for the blades. I decided
to make a blank of blades and shaft in a single piece
of ply. All I had lying around was some bc pine in 3/8-inch
thickness, so I used that. I also had a douglas fir
offcut in 1/4 by 4 by 8 feet. I cut that in inch-wide
strips. The three pieces went together with Elmer's
glue.
Today
I sanded the blank smooth and fixed a few imperfections
with Elmer's glue and wood flour as a putty. The paddle
is cute. Hope it works OK.
The
3M 5200 compound that I used on the hull is still tacky
after 48 hours. I rubbed some wood flour into it. I'm
going to start priming tomorrow.
Time
spend so far:
Add four hours of paddle-making, for a total so far
of 45 hours.
Cost
so far: Add $5 for plywood for the double paddle,
for a total so far of $171.12.

One
piece of bc pine six inches wide and 7 feet long; two
pieces of 1/4 by 1 inch douglas fir. This is all it
takes to make the double paddle. |
|
The
Quark weighs almost nothing, so it was nothing much
to stand it up on end to make room for the paddle
project. The plywood blank is cut out and maked with
a center line and outside lines for the fir sandwich
pieces.
|
|
The
sandwich is buttered and done, and clamps are in place. |
|
Darn,
it's cute! |
|
Final
sanding done; double paddle is ready for varnish. |
|

Prime
time
27
April 03: Yesterday
I put the first of two coats of white Interlux primer
on the Quark; today I added a second coat. Also yesterday,
I did a lot more shaping and sanding on the paddle.
I spent a long time on that because I've not made a
paddle before. I used hand tools rather than power tools,
to get a better feel for the project.
Today
I also used 3M's blue masking tape that can be put on
a drying paint surface as soon as it stops being tacky.
This allowed me to mask off the gunwales for an initial
coat of varnish over the undercoat already in place
of epoxy. Tomorrow I'll put on the first of two coats
of yellow Interlux Brightside paint, and I'll also put
on the first of many coats of linseed oil and turpentine
on the inside of the hull.
We're
planning a launch next weekend to celebrate the filling
of the Erie Canal.
Time
spend so far:
Add eight hours of paddle-making and painting, for
a total so far of 53 hours.
Cost
so far: Add $5 for 3M blue masking tape,
$10 for primer, and $29 more for epoxy for a total
so far of $206.12.
| Last
look at the natural look. Blue 3M special masking tape
in place over gunwales. White stuff is 3M 5200 compound.
Remind me to try bondo auto body putty next time. The
5200 sucks as a putty because it takes so long to set
up. |
|
First
coat of Interlux primer in place. I used latex house
paint and primer on the Weekend Skiff and was not
at all pleased with the results. I used Interlux primer
and Bringside paint on the Harmonica and loved it.
I did used some house primer on the inside of the
Harmonica but not on the hull.
|
|
I
anticipated that the paddle would take a bend unless
I was extremely careful in the laminating, but I decided
that some arc would be good, and that's what I got.
I took the block plane to the paddle and fined down
the outer plies where they sit atop the paddle blade
portions. |
|
After
thinking about it for a while and being uneasy about
the lightness of the paddle, I epoxied the entire piece
and covered all the blades except for the central rib
portion with fiberglass cloth. I figured that without
some help the paddle would snap or split the first time
I used it to fend off. I was in my usual state of hurry
concerning epoxy, so I put the tape on both sides. The
tape didn't cover the edges at all, so I put on an extra
piece folded over the tips and used the 3M blue masking
tape to hold the mess in place while it sets. This will
make the paddles a lot heavier but also infinitely more
durable, too. |
|
The
beauty of that blue masking tape is that you can apply
it as soon as paint skins over. That was about an hour
for the primer. This allowed me to put on the first
coat of varnish on the same day as I applied primer
to the hull. Tomorrow I paint the hull with yellow Brightside
Interlux. |
|
Quark
taking shape nicely. |
|
Closeup
of the top of the stem, with 1/2-inch hole for painter.
It looks like a salamander to me. |
|

Putting
on a second coat
29
April 03:
It strikes me that I'm almost done with the Quark project.
I put on the second top coat of yellow Interlux Brightside
paint today and another coat on the trim and the interior.
We're planning a launch for the coming weekend.
The interior coat of equal amounts
of linseed oil and turpentine will take a lot longer.
The mantra is this: One coat a day for a week, one coat
a week for a month, and one coat a month for a year.
I first encountered this mixture as a way of rejuvenating
wood. A friend gave me a gallon of the stuff that he
had left over after attacking some aging paneling for
a client. I made a pair of end tables a few years ago
and used linseed oil and turpentine instead of polyurethane
varnish. It is still good, and the finish is low gloss
-- almost no gloss -- and the grain is well defined.
No need for any wood stain, which I never use if I am
the one who is deciding what the finish should be. Last
year, I read a letter in Messing About in Boats from
a guy who used the mixture on the interior of a dink
that he stored in his leaky barn for the winter while
he went off to Florida or somewhere. When he returned,
he found the dink full of water but with no lasting
harm. He credited the linseed oil and turpentine mixture.
Another plus is that the turpentine cleans the surface
that it is applied to, so there is no need to worry
about dust or sawdust that you might have missed in
prepping the surface.
I
attacked the double paddle with the sander today, too,
and put on a coating of varnish. By the way, when I
say varnish, I mean Pettit high-build spar varnish,
which I get from ClarkCraft. The paddle is much stronger
because of the fiberglas tape I put on the other day,
and I'm satisfied that it is the best paddle I could
have made in the 10 hours I spent on it.
Time
spend so far:
Add 11 hours of paddle-making and painting yesterday
and today, for a total so far of 64 hours.
Cost
so far: Add $10 for Interlux Brightside paint
(I used about a half pint that I had on hand; it costs
about $22 per quart) for a total so far of $211.12.
| Two
coats of yellow boat paint later, the Quark project is
almost done, except for repeated coats of linseed oil
and turpentine on the interior and another few coats of
marine varnish on the gunwales and thwarts. And some sort
of flotation. |
|
This
is the paddle after an application of epoxy overall
and fiberglass tape on the blades. I was skeptical
about using the blue 3M masking tape to hold the fiberglass
tape in place over the edge of the blade end, but
it worked fine. Just expensive.
|
|
I'm
pleased with the finished paddle. I hope it works well
in the water. |
|

Launch
... lurch ... go home
03
May 03: The
day was beautiful today, clear, cool, and sunny. Not
a cloud in the sky, and 58 degrees F. when I launched
Quark at Widewater on the Erie Canal in Lockport. It's
a short and disappointing story from here, though, because
as soon as I sat down in the boat and pushed off, the
sideways rocking, paired with freeboard of a scant six
inches, shipped enough water to cast me out and turtle
the boat. The good news? Only an elderly lady in a big
sedan next to the launch saw what happened; I was only
in a foot of water; and the water, though wet, was not
that cold.
I
didn't cry, but I didn't laugh, either. I liked building
this boat, and expected to be able to use it. At this
point, though, I don't recommend it for anyone, though
I do plan to see how the 50-to-100-pound contingent
of my extended family fares with Quark this summer,
under careful supervision. Shucks, I plan to try again
myself. After all, I was sitting on a safety cushion,
and maybe being three inches lower would make enough
difference to at least paddle around in warm water.
I'm sure it will be fine for little people.
Time
spend so far:
Add 11 hours of paddle-making and painting yesterday
and today, for a total so far of 64 hours.
Cost
so far: Add $10 for Interlux Brightside paint
(I used about a half pint that I had on hand; it costs
about $22 per quart) for a total so far of $211.12.
It's
a one-person job to get the Quark onto the rack in the
pickup truck. |
|
At
Widewater on the Erie Canal in Lockport. Ready to
launch.
|
|
Ready
to go home. Taking on water after a second try at making
it work for me. At 200 pounds plus, I'm just too big
for this fine little boat. |
|
 
Redemption
for the Quark
03
July 03: Although
I was disappointed and depressed after my initial
launching,
and dunking,
in the Quark, I have not given up on this little boat.
I love its lines, and I've been using the experience
of capsizing this spring to learn more about boat
design. One thing I did was take out the plans and
look at them; I noticed that the displacement is 215
pounds and other reading helped me see what you probably
knew -- displacement includes the boater and all gear.
This boat weighs about 30 pounds, so it is a stretch
for me to expect it to float with me in it.
Not
only did it float with me inside, it floated for two
others, too. We all felt that the boat was tippy,
but none of us got wet. I found that paddling was
the problem; a longer double paddle, with more weight
in a larger diameter shaft would put some weight outboard
and make paddling easier, too.
I'm happy that this little
boat is proving itself, so I'm planning to offer it
for sale through Messing About in Boats -- $250.
| Ellicott
Creek Park was the scene of the Quark's redemption. The
occasion was a picnic for the
Reverend's staff at Concern Ecumenical Ministry. Boater
No. 1 had no problems other than tippiness. |
|
Boater
No. 2, a foot taller but still well within the weigh
limit, had no problems other than tippiness.
|
|
Boater
No. Three, yours truly, had no problems except for tippiness.
It is a responsive and lively little boat. |
|
Another
view of my time in the boat. The bow is just clear of
the water. The Reverend took the two pix of me. |
|
Little
boat back where it belongs. |
|
 
|