Welded Steel
Building Frame |
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The building frame or strongback is typically made of wood. This
building frame was made of welded 2" x 4" tubular steel
left over from the construction of a metal "sculpture studio"
roof. (This studio just happens to accommodate the Caledonia
Yawl!) |
Mic
and Ken
Setting Up
Moulds |
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Spreaders or spalls made of 2 x 2's are attached at the bottom
of each mould. The spreaders are fastened to the steel building
frame with self-tapping screws. Initially, all moulds are lifted
a fixed small amount above the building frame with wooden spacers
or shims. |
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Mould Alignment |
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Steel rules clamped to the moulds are used to check alignment.
The wooden shims between the spreaders and the building frame
are changed in thickness as needed to rotate or lift the moulds
into proper alignment. |
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Stem-Shaping
Blocks Fastened to Table |
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Wooden blocks define the curves in the stems. Clear packaging
tape is used to keep the stems from being glued to the blocks
and table. |
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Mic Checking
Clamps on Just-Glued Laminated Stems |
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Strips of southern yellow pine, 2" x 1/4" in cross
section, are ripped from 12" x 1 1/2" x 20' boards
using a circular saw and a carefully designed jig. The inner
stems are laminated first. After the epoxy from this lamination
is cured, the outer stem laminations are glued together and clamped
against the inner stems. |
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Foreward
Inner Stem |
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The stems are attached to the moulds and building frame first. |
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Aft
Inner Stem and Keelson |
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The keelson begins as a 13' x 4" x 1" piece of yellow
pine. A slot for the centreboard is cut, and then this piece
is glued to the stems using clamps to force its slight curvature. |
Forward
Inner Stem and Keelson,
Closeup 1 |
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Brackets, screws, nuts, and bolts are used to hold the backbone
firm against the moulds and maintain the curvature of the keelson
while the hull is being planked. |
Forward
Inner Stem and Keelson,
Closeup 2 |
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Stems and kelson are rough shaped with a hand saw and chisel
and then faired with a block plane. |
Aft
Inner Stem and Keelson,
Closeup 1 |
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A 2 x 4 spacer between moulds, rather than a 2 x 2, is needed
to hold down the aft end of the keelson. |
Aft
Inner Stem and Keelson,
Closeup 2 |
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The centerboard slot and the curvature in the aft end of the
keelson can be seen in this picture. |
Aft
Inner Stem and Keelson,
Closeup 3 |
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The foreward end of the aft inner stem is shaped according to
the plans. |