Side Boards
plane side boards to 11/16 (sand to
5/8 later)
side boards should be about 12" 6" +
to end up with a boat 12' 3".
using Official specifications, layout
heights desired on one side board
use 13' long flexible batten to get
continuous curve for the top of the sides.
Recommended heights at stations; 0 -3
31/4", 1- 4 1/2, 2 - 5 7/16" , 3 - 6 1/8", 4 - 6 5/8", 5 - 7",
6 - 7 1/16", 7 - 7 ", 8 - 6 5/8", 9 - 5 7/8 " , 10 - 5", 11 - 3
7/48", 12 - 2 5/8", 12"3" - 2 1/4" these will vary slightly
at station 4 where steering (tiller)
post is, should be less than 6 3/4" to work with Sarns standard
steering post. Sarns will build a long post if desired. Check
dimensions of post and head and remember 1/8 plywood for deck
and bottom
cut out side and leave line to be
sanded down latter
lay cutout side board on second board
mark and cut
mark top of side boards into thirds
(two marks) in stern area about 32 inches long
cut 2 slots in both side boards on
band saw with 1/2" blade. recommend 6 teeth per inch to clean
out saw cut, using a tall fence and cut slowly use finger guide
to hold against fence!
trial fit side board in jig before
gluing!!!
use plenty of epoxy a hack saw blade
will assist in tight areas
pull the bends into jig slowly and be
sure all three cut pieces line up at top and bottom before
tightening them down
dry in jig for at least 24
hours
set side boards in bow jig,
tighten against jig, check bottoms for level (be sure you have
wax paper down so drips do not stick)
If you wish a narrower entry or width
of bow make adjustments here.
cut bottom center board (11/16" X 2
1/2 X 12'3"), to fit bow and stern widths as desired
cut slot in bottom board in rear area
about 26" in from end. This is for 1/8" plywood for fore and
aft bulkhead stiffener behind seat under deck.
forward bulkhead location dimensions
should be (1) 54 1/42", (2) 41 5/8" (3) from bow approximately
cut bulk heads with angled sides for
(1) front of cockpit, (2) under mast step, (3) between mast
step and bow these should be from 11/16" Sitka left over from
side boards.
you will need to cut bulkheads ( 1
& 2) to fit bottom board and top board between bulkheads
(1) and (2) for mast step to sit on be sure it is long enough
for front of mast adjuster to screw into.
make bow block from Sitka or pine at
least 8 inches long
cut out bow block to fit
angles
cut out stern blocks one on each side
of bottom center board top & bottom
glue all of the above in with epoxy,
check alignment fore and aft as well as vertical!!! {This set
up determines whole boat alignment}
cut 11/16" x 2 1/2" by 16" Sitka for
Mast Step top of box
cut 1/8" plywood to fit each side of
mast step box
cut Sitka pieces to fit inside of mast
step box - two in middle 11/16" and one at each end to glue
plywood too these should be 3/8" and glued to
bulkheads
epoxy inside of pieces in mast step
box glue all sides then epoxy the rest of the box and plywood
sides
cut pieces for seat bulkhead 1" X
11/16"
front of seat will be about 60" aft of
forward cockpit bulkhead or no more than 110" from forward
steering post
seat angle should be 36
degrees
glue in seat bulkhead pieces check for
square to boat
cut top stringer board for back deck
support, needs slot for 1/8" plywood vertical fore and aft
stiffener
epoxy in above plywood and top
piece
mark and cut out cockpit floor
check for fit and then cover with
fiberglass if desired.
when floor is dry install on floor
stringers (installed below)
cut pieces from Sitka for cockpit
floor to rest on, as well as plank attachment blocks
epoxy in above pieces
epoxy inside of sides behind seat
bulkhead and in front of cockpit forward bulkhead
fillet all areas on both sides of all
bulkheads except inside cockpit (epoxy with 404 mixed to
consistency of peanut butter) use large stirring
stick
route in slot to install 1" x 3/8"x
app 24" piece from bulkhead (2) to nose piece to support
deck
use square to check sides and top,
sand as necessary
glue in cockpit floor
cut foam to fit between stringers in
cockpit floor
epoxy foam to bottom of cockpit floor
and edges
mark out bottom two 1/8" plywood
pieces, seam should be right on cockpit front, bulkhead this
keeps it away from mast step providing more
strength.
cut out rear and front deck 1/8"
plywood pieces and epoxy inside
glue top decks on
check glue areas and fillet in mast
step area epoxy inside of deck areas
epoxy insides of bottom
plywood
glue bottom plywood pieces in
place
make knee using 2 - 1/8" plywood and a
3/8" piece of Sitka glued together
use trim router with ball bearing to
trim edges of plywood, sand only as necessary
cut out seat back supports and glue in
these pieces
cut out seat back use two pieces of
1/8" plywood glued together
glue in seat back
cut out cockpit trim pieces and glue
on
trim off cockpit trim with router,
sand as necessary
sand all sides, decks and cockpit
areas with 150 grit with palm sander
set knee app. 22" aft of cockpit
forward bulkhead epoxy in place
epoxy all surfaces, two/ three coats
(use foam roller and foam brush to brush out bubbles) I
recommend 207 hardener for final two coats it has UV protection
and brushes out easily like varnish, less sanding
use Scotch Brite & water between
coats and wipe with rag immediately to remove Amine Blush (wax
like looking coating over the hardened epoxy this is very
important)
drill holes for steering and all
fittings, steering hole should be about 6 1/4" from nose which
will fit in rear hole (slot) of Sarns stem fitting
fillet cockpit areas use popsicle
stick and then chisel to clean near fillets
sand all surfaces smooth for
varnishing (this smoothness is critical)
varnish all surfaces with three coats
(marine spar with UV protection)
mount hardware
Mast step 40 7/8" + 1/8 - 5
7/8"
Steering 46" + 4" - 2"
Bob stay fasten rear at 8' 4"
approximately
Plank attachment 104 1/2" to
116"
Bob stay post install in middle of
mast step structure.