Day 2 - Tuesday

_____ 2.2.  Starting at the transom, with the inner keel in place, lay the pre-cut bottom boards on the boat bottom in the order shown on Exhibit 1 - Bottom Board Layout Sheet (PDF).

_____ 2.3. Place the first bottom board so that it overhangs the transom by 3/4 inch.

_____ 2.4. With that bottom board held in place, countersink two 1/8” pilot holes in each end. CAUTION! Carefully angle the pilot holes so the screws enter the chine and transom at the correct angle.

_____ 2.5. Apply a bead of caulk along the seam between the chines and the sideboards and along the center of the transom.  The caulk line should be approximately the diameter of a pencil.

_____ 2.5. Apply a bead of caulk along the seam between the chines and the sideboards and along the center of the transom.  The caulk line should be approximately the diameter of a pencil.

_____ 2.6.  Secure the first bottom board to the chines, sideboards, and along the transom with 1-5/8” screws, taking care to angle the screws correctly.

Builder's Tip - It is very difficult to remove caulk from our boards when it squeezes out and has a chance to dry. If you do get squeeze -out, wipe it up and dispose of the surplus in a trash can. Please be careful not to track caulk around your workspace or on the concrete floor.

_____ 2.7. Center the inner keel (keelson) and clamp it tightly against the bottom board.  Do not glue the inner keel.  Secure the first bottom board to the inner keel with two 1-1/4” screws. The screw pattern is front left and back right.  To avoid interference when installing the outer keel, start the screw pattern at the back left and then the front right.

_____ 2.8. Continue fitting the bottom boards together snugly but without using excessive pressure. A small gap is permissible. Continue applying caulk as you attach each board. Avoid leaving gaps in the caulk line, particularly between boards. Have the Crew check any boards that do not fit together before attaching.

_____ 2.9. Trim the ends of each board using a pull saw held firmly against the sideboard.  Carefully drawing the saw up along the sideboard helps to cut the bottom board at the same angle as the sideboard.  Trim each board as you go and take your time.

_____ 2.10. Stop fitting the bottom boards after board #26 (shown on Exhibit 1 - Bottom Board Layout Sheet (PDF) as 20 inches long, near the stem). The Crew will trim boards #27 – #29 to the appropriate width.

_____ 2.11. Install bottom boards #27 – #29 after trimming them to the correct width.

STOP! Do not proceed until you have a Crew Check.

Step 2 - Installing The Keel

_____ 2.12. With the bottom boards attached, install the outer keel.  Center the keel and draw lines down both sides to mark its location.

_____ 2.13. Fit the skeg into the keel slot as you attach the keel. Avoid pinching the skeg too tightly in the keel slot.  Align the skeg and keel with the rear of the first bottom board. Attach the keel by countersinking two 2” screws into each bottom board, one on the back left and one on the front right of the keel (opposite the pattern used to attach the inner keel). These 2” screws will screw into the outer keel, the bottom boards, and into the inner keel.

_____ 2.14. Trim the skeg and keel to align with the rear of the transom if needed. Pre-drill the skeg for the 2” screw, then attach the skeg with a 2” screw angled to enter the transom. 

_____ 2.15. At the stem, trim the keel and bottom board so they are even with the sideboards and flush with the inner stem.

_____ 2.16. Remove the skeg, then sand and paint the skeg and the bottom. No filler is required on the bottom.

STOP! Do not proceed until you have a Crew Check.

Day 2 is done - time to clean up and celebrate!