Day 1 - Monday
~~~ Getting Started ~~~
Every morning starts with a daily overview.
Listen for the Bosun's Whistle at 8:00 a.m. sharp!
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Day 1 - Step 1 - Set Up Your Sawhorses
_____ 1. Unfold your tarp.
_____ 2. Place your sawhorses approximately 9 feet apart in the center of your tarp.
_____ 3. Use blue painter's tape to fasten the corners of your tarp down - do not use duct tape or any other type of tape or glue.
_____ 4. Select a straight sideboard (3/4” x 5 1/2” x 14’). Make sure that it does not have a bevel on one end.
_____ 5. Center, then clamp, the sideboard to one of the sawhorses. The top of the sideboard should be about 1/2" lower than the top of the sawhorse. This board will support the sideboards during bending and, eventually, the stern of the boat.
_____ 6. Confirm that the sawhorse and the sideboard are level; adjust your clamps or use shims as needed.
_____ 7. Confirm that the second sawhorse is level; use shims as needed.
A straight sideboard is attached to a sawhorse with hand-screw clamps and leveled. Thia board should be centered left to right on the sawhorse.
Day 1 - Step 2 - Fasten the Sideboards to the Inner Stem
_____ 1. Select an inner stem. It will be marked "IS" on one end and "Bottom" on the other end.
_____ 2. Select a pair of sideboards that have been pre-cut with 6-degree angles on one end. Line up the edge of the 6-degree cut end of the sideboard with the front edge of the stem. The front edge and bottom of the sideboard must be flush with the stem. Clamp the inner stem and the sideboard together using a hand screw clamp.
Hand screw clamp placement.
_____ 3. Drill three (3) evenly spaced 1/8" pilot holes approximately 1 inch from the front edge of the sideboard.
_____ 4. Remove the hand screw clamp and repeat the process for the other sideboard. There are now three (3) 1/8" pilot holes in each sideboard with corresponding holes in the stem.
Top view of assembly with hand screw clamp. After the first two screws are attached, remove the clamp and insert the third screw with a fender washer.
_____ 5. Use a bar clamp to secure one side of the sideboard vertically to the sawhorse. Check whether the stem stands vertically and leans forward when the bottom board is level and plumb (i.e., straight up and down) at the stern support. Correct placement and alignment are critical; if in doubt, request a Crew Check.
____ 6. Apply 4200 Fast Cure Marine Adhesive Sealant to the stem where the sideboard will be fastened. Avoid covering the pilot holes on the stem with adhesive. You will need to be able to see the pilot holes to make sure the sideboard screws enter them properly.
Starboard sideboard attached to the sawhorse with a bar clamp.
_____ 7. Screw two (2) two-inch (2") screws with fender washers into the sideboard until the tips of the screws are visible. Align the screw tips with the stem pilot holes and fasten the sideboard to the stem. Add the third screw after fastening the sideboard to the stem. The fender washers prevent the screws from pulling through the sideboards during the bending process.
The starboard sideboard is attached with 2" screws and fender washers. The port sideboard is now ready to be attached with 2" screws, fender washers, and 4200 Fast Cure Marine Adhesive Sealant.
_____ 8. With the stem facing up, repeat the process of fastening the other sideboard. The "V" should be flush, with the stem leaning forward.
_____ 9. Remove the sawhorse bar clamp.
_____ 10. You are now ready to start the bending process.
STOP - DO NOT PROCEED UNTIL YOU HAVE A CREW CHECK!
The bow stem leans forward, and the front of the "V" should be flush in the completed assembly.
Day 1 - Step 3 - Attach the Sideboards to the Transom
_____ 1. Measure along the top edge of the sideboard from the front of the bow stem, and make two marks on the top of the sideboard, one at 72” and one at 73 1/2”.
_____ 2. Do the same on the other sideboard.
_____ 3. Place the spreader board between the two lines.
The spreader board will be removed later. Do not glue the spreader board to the sideboards.
_____ 4. Wrap a line around the ends of the two sideboards about 3” or 4” forward of the double marks on the sideboards, with an eye at one end. Tighten the line by pulling the line through the eye. As you pull the line through the eye, hold the line tightly at the eye with one hand, and continue to pull the line through the eye with your other hand. When the sideboards are against the spreader board, tie off the line.
_____ 5. Line the spreader board up between the 72” and 73 1/2” marks. Use one 2” screw to attach each sideboard to each end of the spreader board. Remove the line after the sideboards are attached to the spreader board.
Do not glue the spreader board to the sideboards.
_____ 6. Remove the extension board from the top of the spreader board and return it to the stage.
Spreader board positioned with stern tied off.
_____ 7. Each sideboard has double 12-degree marks near the ends of the board. This will be the location of the transom. Secure a 12" hand screw clamp to each sideboard along the 12-degree mark closest to the stem (toward the front of the boat). Reposition the line around sideboards directly ahead of the hand screw clamps (toward the stem) and pull the line through the eye until the sideboards are approximately 31” apart at the double 12-degree marks. Tie the line off.
_____ 8. Unclamp the 14' sideboard from the sawhorse and return it to the stage.
_____ 9. Select a transom and place it against the clamps.
_____ 10. Position the boat so the sawhorse is directly below the 12-degree marks, and the transom is sitting on top of the sawhorse.
_____ 11. Check that the tops of both sawhorses are level and that the bow stem is vertical.
If the bow stem is NOT vertical, request a Crew Check.
_____ 12. The transom is held higher than the sideboards by temporary spacers (the white tabs) attached to the bottom. These spacers keep the inside edges of the sideboards aligned with the bottom of the transom. The temporary spacers will be removed later.
Sideboard & Clamps
at Transom Marks
Day 1 - Step 4 - Attaching the Transom
_____ 1. Before fastening the sideboard to the transom, be sure that the transom and sideboard are resting on the sawhorse, and the inside edge of the sideboard is in line with the bottom of the transom. Pre-drill the sideboards to accept the transom screws.
_____ 2. Secure one sideboard to the transom at a time. Apply a bead of 4200 Fast Cure Marine Adhesive Sealant between the 12-degree marks. Place the transom inside the marks.
_____ 3. Use the 12” hand screw clamp as leverage to bend the lower portion of the sideboard tight against the transom.
_____ 4. With the sideboard tight against the transom, start with the bottom screw and fasten the sideboard to the transom with three (3) two-inch (2”) screws and fender washers. Repeat the process for the other sideboard.
_____ 5. Secure the other sideboard by twisting the line (Spanish Windlass) and a 12" hand screw clamp until the remaining sideboard is tight against the transom. Use a small board to twist the line. The line will hold the sideboard in place while the transom is being fastened. If the sideboard does not fit tightly against the transom, you may need to adjust the alignment. If needed, see Day 2 - Step 1 - The Bottom - Adjust Alignment.
Do Not Remove The Spreader Board.
STOP - DO NOT PROCEED UNTIL YOU HAVE A CREW CHECK!
Transom in Place with Hand Screw Clamps
_____ 6. Once you have completed your Crew Check, turn the boat bottom up. Many hands make this an easy task!
_____ 7. Check to see that the inside edges of the sideboards are even with the transom. The level should be resting on the outer edges of the sideboards and should be approximately 1/4” higher than the transom.
_____ 8. Remove the spacers from the transom.
Day 1 - Step 5 - Install the Chine Boards and Rack the Frame
_____ 1. Cut one end of a 3/4" x 2 3/4" chine board to match the angle of the transom.
_____ 2. Clamp the chine board to the transom to hold it in place while bending. (ADD IMAGE - Chine and Sideboard)
_____ 3. Clamp a scrap board to the sideboard to hold the chine board while cutting it to fit. (ADD IMAGE)
_____ 4. Cut the chine board to fit. Use a bevel square to determine the angle of the cut. (ADD IMAGE)
_____ 5. Bend the chine board and clamp it to the sideboard. It is VERY IMPORTANT that you secure the chine board tightly against the sideboard. If the chine board is not tight against the sideboard, the ribs will not fit properly when they are installed. (ADD IMAGE)
_____ 6. Lay a 4' level across the chine board and the sideboard. Make sure the outer edges of the sideboards and the outer edges of the chine boards are level and are at the same height as shown in this image. (ADD IMAGE)
_____ 7. Make sure the inner edge of the chine board is even with the transom. (ADD IMAGE)
_____ 8. With the chine board in place, use 1 1/4" screws to fasten it to the side board every 8" from the outside of the boat. Countersink the screws.
_____ 9. Repeat the process for the other side of the boat.
_____ 10. Lay a 4' level across the boat. Plane the chine board and sideboard until the level sits flat. There should be no daylight between the level and the top of the boards.
STOP - DO NOT PROCEED UNTIL YOU HAVE A CREW CHECK!
Day 1 is done!
It is time to clean up and celebrate!
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