I finally received my plywood and started my Skerry. It is a bit intimidating really.

The scarf joints got better as I went along. |
Cutting scarf joints in panel to make the pieces long enough is surprisingly simple. I made a router jig but it turned out that cutting by hand using a block plane is faster and more accurate. I suppose it is hard to make a perfect joint but I'm hoping that at least one side will look good enough to keep natural colour. The worse side will go to the outside and be painted. |
 Scarf joint clamped. |
Gluing the scarfs is a bit scary at first. I taped both sides of the joint then used wax paper instead of plastic wrap. It behaves better and doesn't stick to itself like plastic wrap does. I tried to make at least one of the 2 sides match perfectly. I'm hoping to fill and paint one side and keep the interior bright. I carefully unclamped while still a bit soft and cut off the epoxy that had squeezed out. |
 Checking the instructions. |
Check twice cut once! |
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Transferring the measurements to the boards. I snapped a line for the middle and made my marks on tape. It is easy to change when a mistake is made. I used a long thin board to join the points. I'm quite accurate mostly but at one point the point was about 1/8 inch off. I'm hoping this will dissappear under the fillet later.
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Lofting I think it's called.
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Cutting along the lines I drew. I bought a couple dozen saw blades and change them as soon as the cut starts to get messy. I found that a coarse metal blade works better than a wood blade. Its quite slow but does not leave a burr. It is hard to make a perfectly smooth line though and I'm hoping little jumps will dissappear after sanding/planing.
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Using a saw to cut on the lines on the bottom piece. |

Cutting side pannels |
After setting up the 16 feet side blanks and transferring the points by measuring and using a flexible stick to join the points between measurements I was ready to cut the sides. I checked twice and still expect to find something wrong. Murphy's law is alive and well in my home!! Although the process is not difficult in itself, it is ackward to manipulate the big floppy pieces of wood. I cut 2 panels together for each side. That way if there is anything a bit off at least it will be symmetrical.
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I now have all the pieces of the boat cut out except for the mast step and the reinforcement on the bottom of the front seat. I will wait till I have an exact diameter for the mast. I'm substituting a round mast for the square one in the design. For no other reason than I like round better. The rabbets have been cut in and that went very easily. The router cut the plywood smoothly and easily. The short tapering rabbets which blend the panels front and back however were much harder to cut. The little plane kept getting caught up in the plywood cross grain. I finally used a sharp scraper and this worked better. A bit of sanding finished the rabbet.
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Side panels |

First hint this might end up looking like a boat after all. |
After much fidling and making of small holes for the copper wire, I have started the assembly. The base and first panels did not fit perfectly. The base was about a half inch too big. I did some "adjusting" with my block plane and now things will be coaxed together without too much fuss. I'm depending on the filling putty to hide any imperfection where the end of the base and the front meet. I've only roughly tied the base to the first panel. I'm thinking I'll adjust everything when the third panels have been added.
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I added the 3 frames and they went in without too much trouble. They are only tied to the base at this point. Second panel was more docile than the first and attached itself to the first without much argument ... yet. Boat certainly is big. Fills my living room quite completely.
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Side panels |

Bulkhead wired, and third Panel in place. |
What a day! 2 steps forward, one step back. I finally managed to get the bulkheads wired in proper position. Not easy because the panels have to be coaxed and curved into position and its hard to do. My wires kept breaking and wood got a bit scraped on the outside. Not really a problem because it will be painted but nerve wraking. I have a few gaps here and there and I will have to rely on the filling capacity of the epoxy paste more than I had hoped. The hull is quite symmetrical and well formed and I think that is quite important. It actually looks like a boat now. What a treat! After suffering all day I took a break cleaned up the area and took a look.
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 Hull is being glued Detail of hull |
After finishing wiring the third panel, I turned the hull over on workhorses and checked the alignment of everything. In all projects there is a dark and gloomy period where nothing seems right. All I could see were the scrapes, gaps and bits that didn't quite fit right. HOWEVER the hull shape seems to be true. It measures nice and symmetrical still and stems seem perpendicular. There is a ray of hope surely. I started gluing between the wire ties. I was lucky and did not get any drips to the inside. It looks like a boat now and my family actually believes me. Everyone who has actually seen the boat have commented on how nice the lines are!
 Removed most of the wires, put a bit of filler epoxy in the wire holes and started pouring epoxy in the channels made by the panels. Epoxy is a wicked material that flows mercilessly and can get through 1/16th of an inch! So I taped the inside seams with masking tape. This made my job easier. The outside ridges are supposed to be nicely filled with epoxy using a seringe. That part I had no problem with, but, once in place epoxy very slowly creeps downhill and starts dripping at the bow and stern. I expect I will have to fine tune my hull! (read sand a whole lot.)
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After turning the Skerry over, I filled the inside stems with a thickened mixture of epoxy. While everything was still wet I put on a fiberglass strip and painted it with epoxy. Except for the annoying little threads of fiberglass things went very well. The epoxy did its best to flow to the bottom of the boat but I was merciless in sopping it up. Tacked the 3 bulkheads with thickened epoxy.
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 Hull Glassing the inside bow and stern. |
here
 Masking tape between bottom and second panel. Trimming fiberglass cloth to exact size. |
I got up early to work on hull. Sanded all the touch-ups I did last night. Vacuumed and dusted the hull. Erased a few lines I had made. I think I'm ready to epoxy the inside. I measured and rough cut the fiberglass cloth so it would be all ready. I taped the seam between second and first panel so it would be easy to clean up. I then made a thickened epoxy mixture and smoothed out the bottom - first panel seam with a smooth fillet. The seam was pretty rough I'm afraid it might show up. After trimming the epoxy cloth to size I made sure everything was ready for resin.  Resin soaking in cloth.
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Resin is nasty stuff. It crawls down any incline and is determined to make runs and puddles! Wicked I say. Managed to get the resin spread out with minimal runs. I have a couple of puddles though. I let things harden up a bit then trimmed the extra cloth and removed the tape. It now needs to set a bit longer before I can put my first over all coat of epoxy resin on the inside.
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 Inside bottom and first panel have a coat of fiberglass cloth and resin. |