Building Short Shot – part 2

This boat is going together quickly. Part of this I attribute to stumbling on a much faster way to lash the joints. I have always done them one joint at a time. Since this boat is multi-chined there are a lot of joints. Matter of fact, there are 9 going from one gunwale to the other. I have always been a little concerned about lashing all the joints instead if lashing them one at a time but I decided to give it try.

I pulled off nine times as much sinew as I normally do. I quickly realized this was going to be a mess so I cut a piece of 1″ dowel and wrapped the sinew around it. Once I tied off the end I started feeding the dowel with sinew around the gunwale. Right off the bat I found it saved a little time because I didn’t have to find my dowel or a block of wood to wrap the sinew around to pull it tight. I just used the the spool I had the sinew wrapped around.

Since I don’t have to tie it off, cut a new length of sinew, tie the stopper knot and then start lashing 9 times I have found it is MUCH faster. I suspect it is at least  twice as fast as doing individual lashings. My only concern was if a lashing breaks or is damaged and having nothing to stop it from coming undone. Of course, I have never had a lashing break in all the boats I have built so I don’t really see this as being a problem.

So far I have 16 hours labor in it and the cost to this point is $150 (rounded off). I estimated a couple of those figures so that may change a little.  That includes so far, plans, plywood, cedar for the stringer and sinew. I don’t count the strongback because it is not part of the boat and it can be taken apart and recycled for another use.

Stringers and frames held together with bungees.

Stringers and frames held together with bungees.

Lashing the frames

Lashing the frames

Frame starting to take shape.

Frame starting to take shape.

Building Short Shot – part 1

Recently I had a discussion with a client in the forum about the cost of building a boat. His values seemed high to me and I realized he was counting some things other than just his materials. In the course of the discussion I realized that prices have raised enough that my low end figure of $300 was probably not realist for most people. Thinking about costs I started wondered what a ‘well equipped’ kayak, like I typical build for myself costs?

I just started a building a redesigned Short Shot, for my wife, so I have decided to keep track of the time and costs of building this boat and document the building process too. I have a lot of spares and scraps lying around I can use that cost nothing. So, I decided to keep track of two costs, actual costs and what it would have cost me if I had to buy it.

For example I managed to cut all the frames from scraps lying around the shop I have been saving. If you have to go buy it, a sheet of plywood is about $50 in most places so I will use that figure. Stringers, I had the wood in the shop and just pulled it from the rack. It is hard to find so I whenever I see good wood, I buy it. I will have to call the lumber yard and get a price for what the wood costs is.

As you can see from the photos, I have the frames made, the stringers cut and scarfed and glued. At this point I have 11 hours (rounded) in it. I didn’t keep track of my time cutting the frames since I did those a couple of weeks ago but because I cut so many I have gotten really quick at it. To be realistic I used 8 hours for the frames. That is about what it took me when I started. Then 2 ¾ hours to cut the stringers, cut the scarfs, glue them and set up the strong back.
Once the glue dries I can start actually building the frame.

Clamshell strong back

Clamshell strong back

Cutting the scarf joints on my table saw with my scarfing jig.

Cutting the scarf joints on my table saw with my scarfing jig.

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Jigsaw puzzle, ready to be glued up into something useful.

Jigsaw puzzle, ready to be glued up into something useful.

My favorite clamps for this job is PVC pipe.

My favorite clamps for this job is PVC pipe.

Waiting on the glue to dry.

Waiting on the glue to dry.

 

3 boats, 6 days.

Last of of August I was invited to the Chincoteague Bay Field Station, in  Wallop Island, VA to teach a Road Scholar class where each student builds a Fuselage Frame kayak for themselves.

Being a Road Scholar program the staff has also scheduled in field trips such as kayaking, exploring a private beach and educational classes. They also take everyone out to a few local Restaurants. All of which are very good, especially if you like sea food!

The facilities at the Field Station are top notch as is the the staff. As one student said, they over serve you! If you ask for a pencil you will get a handful of them with a sharpener and a smile. The Educators that work with the classes are college grads and most have studied Marine Science or related fields. They are all obviously the cream of the crop and you will not meet one that doesn’t impress you.  The ladies in the cafeteria always provide excellent meals and plan them well. I was last in line one morning and it looked as if they had run out of food. When I got up to the steam table I realized that actually there was just enough for a couple more people. They plan so well that there is just very little waste. It shouldn’t have surprised me because that is just typical of the way everything is done here.

Sunday afternoon the students arrive and check in. I had arrived a day early and prepared my class room ahead of time. I had the strong backs set up, all the tools, frames, stringers, etc. sorted out and arranged at each work station.  It didn’t take long to have the class room in shape so I was free to enjoy a couple of days of paddling.

Sunday night I meet with my students, Parker does the introductions and goes over all the formalities and instructions for the coming week. Then my favorite part, The Boil! These folks start the class right, with meal fit for king! After the meal we visit the class room and show them what they have gotten into. I give everyone a homework project too.the boilMonday morning we meet in the cafeteria and have breakfast together and get to know each other a bit better. This year we were building 3 kayaks, two of my Vardo design and a one Ravenswood.  Once in the classroom I get everyone assigned to their stations. I cover some basics about building, teach them the names of the parts of the boat and I try to get them ‘hands on’ as quickly as possible.

This is where we stopped at lunch, it doesn’t appear we have much done but it is actually a good start. They have a few frames in place and have started to lash them in place.2014 class -1 2014 class -2 2014 class -4It takes the students till the 3rd day to get the lashing to the point where we can take the boat off the strongback. However, these guys were here for one reason, to build a boat! The schedule is flexible and they decided to skip the extracurricular activities to stay in class and work. They even came back after dinner and worked when it wasn’t scheduled.  By the end of the second day they had their frame to the point it had to come out of the strongback.2014 class -8 2014 class -6 2014 class -7We pulled off the frames, lashed the joints you couldn’t get to and then it is time to apply a finish to the frame. Because of the time limitations we use water based poly because it will dry quickly. Since we were a day ahead Wallis and Jim wanted to stain their frame as well as the coaming.

By the forth day, they were all starting to get a little tired from the pace they had been keeping. They decided to take some time off. So, the next couple of days we did some kayaking and went beach combing on Wallops Island, which is a Military base. It is used by the Navy and NASA has a launch facility there. The Field Station works with NASA and is the only group  that gets access to the beach other than those that work or are stationed there. beach beach2The beach was littered with Horse Shoe crabs. I discovered that this is Mecca for Horseshoe crabs!

beach3Tara, one of my educators found this little guy on the beach. I managed to catch him and calm him down. For such a little fellow he was seriously wanting to eat me! I thought it must be a Rat Snake but it turned out to be a type of Garter Snake I had never seen. My other educator Gabe, who was off that morning, was involved with an ongoing snake research project on the Island and told me they were a rare site on the Island. After a few photos, we turned him loose.

With the frame finished they started skinning the boats. I decided to try the Double Corded Stitch for the first time in a class and that was a good choice. It probably cuts the sewing time in half. I was also impressed with how straight their seams were for first timers too. They didn’t realize just how well they were doing though but I was impressed.2014 class -11 2014 class -10 2014 class -9Saturday arrives and it is the last big step, painting. I always look forward to seeing what color everyone picks. I had heard lots of ideas tossed around during the week, but when it comes down to the wire you never know what they will go with.  Don seemed to go the safe route with white, but he had some big ideas for paint once he got home. So he just wanted to white base coat and has promised to send me photos of the finished product. Wallis and Jim…. well, they went bright!

2014 class -132014 class -14 2014 class -12Sunday morning, 50 +/- hours latter we have 3 boats 99% finished. These guys have been hard workers and now it is time for their reward. We work on installing the backbands and painters. Finished any last minute details and it’s time to load up the boats and launch!

Don lived close by and decided to pass on the launching and so not soil the paint since he wanted to do some custom work on it.. He loaded up and said his good byes. And yes, that is a sweet little CJ!

dons ravenswoodGabe and Tara, my most excellent assistants for the week, loaded up the boats on their trailer and we headed the NASA docks to launch.

2014 class -15

launching The smiles on their faces said it all! My camera had started acting up and I didn’t get to take any photos of us outside the harbor. I would have used my phone but there was at least 20 mph winds blowing and I wanted both hands on the paddle! That is a tough maiden voyage but it went very well and the boats looked great on the water.  We paddled around for about an hour and I think no one was any happier than me! I love seeing those smiling faces in their new boats, that they built!