Construction starts
Note: clicking the photos links to a higher resolution image
I start with two sheets of 3/4" AC exterior fir plywood, purchased from the local Home Depot, plus a couple of 2 x 6's that I know I'll eventually need for the strongback. Cost so far: $81. With my large T-square, nails and fishing line, I lay out the frames and transom onto the plywood. The ellipse drawing is pretty easy, but it takes me a while to figure out just how to 'nest' the frames on the plywood for minimum waste. I cut out two of the frames.
The 'cut plan' from my computer. This is not really visible on this webpage, but if you click it, you'll link to a high resolution image that shows how I 'nested' the frames on the plywood for efficient cutting.
I continue cutting out the frames, using a Skill jigsaw. One problem: the crappy surface veneer of the AC exterior fir plywood splinters readily, making a mess of the cut edge. The solution: I lay electrical tape along the cut line, and pre-score the plywood with a cutting blade, before sawing; this dramatically minimizes the raggedness of the edge. I cut the third frame, and the transom. I also begin to 'fill' the frame faces with filler compound (West epoxy and Microlight 410 filler) in order to minimize the finish work after the hull is assembled.
I didn't take any photos of the layout or frame cutting process, so here are a few catboat photos for your viewing pleasure. Hopefully, the Ellipticat will look something like these.
More cutting, this time on the second sheet of plywood. This is getting tedious! To pass the time, my shop TV is tuned to CNN (I'm a bit of a news junkie) and I listen to the controversies of the day. The weather is still decent, no need to operate the kerosene heater (click here to learn about working with epoxy when it's cold). I sand the faces of the frames I've filled.
Another gorgeous catboat.
I cut the last two frames. Lots of plywood sawdust.
I drop by the local West Marine and pick up some additional resin and filler. Cost: $50. Accumulated cost: $131. More frame face filling.
A larger Menger cat.
I finish filling and sanding the frame faces, plus the frame inside edges.
Page log:
Inwales and Interior Fiberglass
The Project Resumes... Floorboards
Essays:
Using epoxy in cold conditions
Errors, bad judgments, and lessons learned