During the winter of 2006 the Saginaw Bay Community Sailing Association is building a Joel White Shellback Dinghy from plans by Wooden Boat of Brooklin Maine.

This is a work in progress with planned completion date of (late) Spring 2006.

The boat building class is made up of about 12 students. The class meets once a week for three hours, with class meetings increasing to twice a week depending on progress.

Week OneWeek TwoWeek ThreeWeek FourWeek FiveWeek SixWeek SevenWeek EightWeek Nine
Week TenWeek ElevenWeek TwelveWeek ThirteenWeek Fourteen Week FifteenWeek SixteenWeek SeventeenWeek Eighteen

Week One
Students get orientation lecture.
Several sheets of marine plywood are planed with a 12:1 scarf so they can be epoxied together to form 12 foot stock from which the hull planking will be cut.
The transom is laid out from a full size pattern.
WEST ® epoxy gets mixed to be applied to scarfs.
Mahogany veneer gets ripped to size for the stempost laminate.
The stempost frame gets shaped to the proper size.
Week Two
The stempost laminates are epoxied together.
The mystery of the planking layout is solved.
Week Three
Through lofting the plank dimensions are transferred from the plans to the stock material.
The midship frame is laminated on the mold station.
A Shellback built two years ago is used as an instructional prototype.
Week Four
The strongback is leveled and braced ready for remaining stations to be installed.
The midshipframe has been cut to final shape.
The bowstem is fitted to the strongback.

The planks are fiberglassed on both sides before attaching to the frame.

Week Five
The bowstem gets shaped to receive the planks.
The transom is attached to the station frame.

The stations are centered on the strongback, ready for the first plank.
The rudder is trimmed to it's final shape.
I know this part goes somewhere?.
Small parts are cut from Mahogany stock.
The bottom plank is set in place.
The remaining planks are cleaned and readied for attachment to the frames.

The bottom is beveled so that the garboard plank lays flush to a good gluing surface.
Now what is it we are supposed to be doing?.

The garboard planks are set in place.

Week Six
The Chief Technical Advisor reviews the plans.
The garboard plank is faired to the bottom.
The middle plank get a rabbet to fit the garboard plank.
The bowstem get shaped to receive the plank.

            The middle planks are are attached to the garboard planks.

The boat takes shape.
The sheer plank get beveled and rabetted.

The sheer plank is test fitted.
Epoxy is applied to the middle plank.
The sheer plank is set in place.
Mahogany and Ash strips are planed and laminated together to form the tiller.

It looks like a boat!.
Week Seven
After the planks are trimmed the boat is cleaned for fairing and application of the epoxy and fiberglass coating..
The boat is temporarily removed from the form to tape any holes before glassing.
A second layer of fiberglass cloth is laid over the boat and epoxy is squeegeed on to wet the cloth.
The glass is split at the plank lap so it lays flat to the plank.
The rudder is glassed and the rudder cheeks are epoxied in place.
Week Eight
A second coat of epoxy is applied to the hull to fill the weave of the fiberglass cloth.

Cleanup begins on the inside of the hull.
The tiller is planed and shaped.

Transom knees and foredeck are fitted to the boat.
The outer hull nears completion.

Week Nine
The interior plank seams are faired with thickened epoxy and tooled smooth with the use of a fillet ball.
The dagger board, rudder, and tiller get final coats of epoxy.

Week Ten
The seat blocks are shaped and aligned.

Week Eleven
The inwales are fit to the knees.
The bowstem is attached to the boat and faired.

The outwales are attached to the boat.

Week Twelve
A student sharpens his tool.
The inwales are attached to the boat.
The gun'ales are faired to the sheerline.
The seats are fit.
The boat nears completion with the gun'ales, seats and daggerboard trunk in place.

Week Thirteen
The seat knees are positioned and attached.
The seats have been removed for varnishing, the gun'ales have been coated with a clear expoxy coating.
The maststep has been installed.

Week Fourteen
The keel is shaped and attached to the boat.

Week Fifteen
The keel is coated with fiberglass and epoxy.

Week Sixteen
The hull is faired prior to painting.
The hull is gets a coat of primer.

Week Seventeen
The hull is gets painted.

Week Eighteen
The boat is ready for the final varnishing.

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Last modified Thursday, 24-Dec-2015 11:04:25 EST