Under Construction

Well, the work in the shop is progressing - thanks to a bad cold, not quite as quickly as I would have hoped.




The strips have been going on nicely, but to get a nice colour balance at the bottom, I've had to play around with some of the strips. Nothing major, but I had to use a couple of old strips to get a nice solid dark cedar in the middle of the canoe. The alternative would have been an inconsistent light/dark blend which I wasn't crazy about.





So, I've built up all one side of the canoe bottom. Next step is to trim off the excess and finish it down to the center line. It's a good thing I put the basswood strip in where I did. The curves to the center get more pronounced as you move in and it was a wrestling match just to get that in.










The old strips I found were as hard as a rock - they had been around for years. It took a pile of clamps and bungees to keep it in place. But the end result should be beautiful.










There is still a pile of work to be done and I'm probably going to be hard pressed to get this finished before May.

Ok - so it's not exactly Lego

So, I've been able to spend more time in the shop with the canoe, and it had been going extremely well up until this week.

The wood I am using is of extremely good quality and the work I put into the forms and strongback have made putting the first few strips on, very easy.

I have a bright basswood accent strip set in between some dark cedar. Once the finish is on, it should come up quite nicely.

This part of the caone is relatively flat, so the strips went on very quickly. Once the first strip is on (the bottom most one in this picture) and perfectly level, it is like putting siding on. A bead of glue in the cove, center the strip on the boat and tack it in to the forms with a finishing nail (just to hold it in place while the glue dries).

But as you get to the "curvy bits", getting the strips to stay snug to the form becomes a little more difficult.

After laying a couple of stips each side, I came back to the shop the next day to see that the boards had come away from the form (despite me securing them with bungee cords while the glue dried). Apparently, this is not uncommon and probably could be avoided if one used narrow strips.

You can see that the form (well used now and is probably having trouble keeping the brad nail from moving around) is about almost a quarter inch from the strip - and this would get progressively worse.

So, off to the web to find some solutions. Al had told me to use a clamping system with wedges that would force the boards into place.

This is the best solution and some forums have also said using a heat gun on the strip before placing it in, leaves it a bit more pliable.

I boiled some water and saturated the wood to get a little more give in it before putting the clamps on. Seems to have worked.

This is going to be slow going for the next few days, but it should work. There is going to be plenty of sanding and "improvisational" carpentry before the fiberglass goes on.

There are systems that allow you to create a cedar strip using only clamps. This way you don't get the small nail holes in the wood. But, I'm guessing that those are a little more advanced than what I'm ready for right now.

Fit, Form and Function

Last Sunday I set up the bow and stern forms and aligned them to the strong back center line with a string. Some things sound deceptively easy when you are writing - it took me at least 4 hours to get this perfect. The idea is to have a perfectly square set forms in all x, y and z axes.

These look like two dimensional mushrooms from this angle, but these forms are what I will be pinning my cedar strips to. The string (which I'm not sure you can see) runs from end to end about an inch above the tops of the forms. Each form has a center line that you need to align to the string and the center line on the strongback - this makes it square in all direction once you screw it into the station block that were put on earlier.

If you look at it from a slightly different angle, it starts to look a little more like a canoe.

Aligning and squaring these took a few extra hands and eyes - you start to see things after a while.

On the fitness front - it was a sorry state of will power this week. I got out to the gym only twice (once for a cardio workout and once for weights) and I only played one game of hockey. The league game this week was late (10:30pm) and a combination of the weather outside and the nice fireplace inside resulted in an instinctive decision.

I'm digging out an old work out routine to mix things up a bit - changing the workout routine every now and then helps.

MoviePix is running a Bond film marathon this week. Some of these bring back memories of the gang going to see these on a Saturday night at the Somerset. Man, some of these are so cheesy when you look back and scenes obviously stolen from previous movies, you'd think they'd never cleaned off the story board.

Casino Royale is on tonight and I have to say I like the grittier, darker bond films - s it's going to be a toss up between Bond or BSG "Razor" .

...and now....the Larch...

Stealing the title from the Monty Python skit seems appropriate. A lot of work went into leveling the strongback....and it doesn't look that much different.

You've seen it before - now here it is perfectly level. (Ooooh and Aaaah at your leisure)

And here it is with a bunch of sticks on it - oh, the craftsmanship!

I am certainly hoping that this weekend gets to be a little more substantial as far as progress.

Al and Ez put on a new coat of varnish on Ezzie's "Redbird".

In the rink -

We had a break last week. A lot of the guys are out on the hunt, sounds like a good year so far.

I had 3 starts in net and won all 3, although there is plenty of room for improvement. A couple of late mistakes in the last game made it more interesting than it needed to be.

The most unpleasant outing I had in nets was this past week. I made all the saves off the first shots, but the rebounds were terrible. All the follow up shots I would get a piece of, but not enough to make the save (this becomes extremely aggravating). It was like that all night.

My league game last night still haunts me. I got the first goal on a decent enough backhand, but the puck was bouncing on everyone during the game. Transitioning from goal to wing is a bit of a challenge. Towards the end of the game, I was fed a beautiful pass that I couldn't (or didn't) adjust to fast enough to get a one time shot off. Instead, I took it in the skates and tried to set up off the kick up (yeah - didn't work so good).

Keeping up at the gym is helping quite a bit. I am usually able to keep my acceleration and speed up throughout the game, which is a good compensation for my lack-of-skill level.

Bends and Boxes

Puttering away in the woodshop is fun. The pace is a lot slower than work and it requires a great attention to detail - which suits me just fine.

So far, the stems have been crudely constructed and need some planing/finishing before being secured to the strongback forms. A couple of days after the pieces were steamed and clamped, they were taken apart and a laminated together using epoxy. Each of the bonding sides gets 1 coat of the epoxy and another coat of epoxy blended with a filler (Carbosil I beleive was the name). The blended epoxy is also coloured with fine sawdust of the same wood you are bonding (ie walnut or cedar in this case).

The walnut laminate is going to be on the outside of the canoe, the cedar on the inside. In this picture there is a layer of wax paper separating each set so they don't bond together. They need to be clamped together on the form to maintain their shape. When they are paired up during the building process, they are going to need to match perfectly. They'll stay clamped together for about a week which will ensure they do not spread (as would be there natural tendency).

The next step is to prepare the strongback, which will need to be perfectly level and square in all planes. The better it is set up, the fewer "adjustments" need to be made later on. It's like the foundation of a house - so it may take a few days to get it set up right.

This strongback is on loan from a fellow canoe-builder, Peter. It's in very good shape and the only thing I've had to do, so far, is to flip the plywood top. It's been used a few times and had earned a few dents and ridges. Once I have it completely square, I'll mount the forms themselves. That might take a bit of tweaking as well.

Of Ice and Wood

On the ice........

I guess the lads on my league team had a bit of a bad outing a couple of weeks ago - so I was tapped to play last week and this week in the pipes. This makes me goalie # 3 so far this year (I usually play forward in this league) - needless to say, I was a bit nervous.......and so was the rest of the team after the first five minutes and a 0-3 deficit. But we did win that one 5-3 and this last week was a much improved 5-1 win.

Try as I might, I have a terrible time with my glove hand - my stick side is great, and maybe that's whats keeping me looking good, most goalies have a harder time on that side, so that's where most of the shots are. I got the glove on ebay, but the manual never came with it.

The regular goalie has a severe ankle sprain and thinks he might be back after hunting season. But I was talking to my buddy at work who has played nets since he was 6 and he told me he had to take almost a full season to recover from a similar injury (it's the stance and the push-off that can be painful during play, you may not even feel it from day to day).

It's still a blast - all the guys know each other and I was filling in for a goalie on a Sunday night pickup game. That was 4 on 4 with some of the better players from my league - I was soaked by the end of the night.


In the shop....

I finished re-cutting the a couple of the forms that had been damaged through previous builds. I might still have to shave down the edges a bit, but nothing major. Tomorrow, I'll be setting up the strongback and setting in the forms. This provides a skeleton to build the canoe on.

My wood is on order now from my canoe place -and I should be into actual construction by the first week of Nov. The big deal this week was forming the stems for the canoe.

Stems are laminated strips of wood at the two ends of the canoe. I had spent a few hours cutting and planing down some strips of walnut for this. Al Witham (who is essentially teaching me how to do this) finished off the cedar and ash strips during last week.

After steaming the stems for about an hour (just bundle the wood together, set it in a long tube overtop a kettle and plug both ends with rags) Al told me that in theory we have about 45 seconds to get these pieces bent and clamped onto the form......but in reality it was probably closer to 15 sec. A weeks work dependent on 15 sec.....boy I love carpentry!.

Everything went well and even Al and my friend Ez were suprised, because no one who made canoes with them had ever tried to bend walnut before (I found this out afterwards).