This shows the staples before they are pulled out the day after they go in. This image is from the 5th day of work on the boat.
This is what it looks like after the staples are out.
A little glue mixed with sanding dust makes a fair filling compound-ugly at first.
After filling and sanding, the hull starts to present the way it will look when finished.
Looks sorta like a canoe now.
End-on this view shows the basket weave pattern used to complete the planking on the hull bottom. A bit more filling and sanding and it will be ready to fiberglass.
The hull is now sanded and the sealer coat of epoxy has been added. this serves to give the epoxy/fiberglass a good bond without the epoxy being absorbed into the dry cedar, which might cause patches in the glass that look dry when complete.
The 1st coat of epoxy goes on. Here you can see the white cloth hanging at the lower edge of the boat. This is trimmed off prior to the 2nd coat
A closer view of the cloth with one coat of epoxy. It's surprising how the texture of the cloth shows here but not the white cloth, as it has now been impregnated with the epoxy. When complete the texture of the fiberglass cloth will be invisible.
A last full-on hull view showing the 1st coat. 3 more coats and the outside of the hull is ready for sanding prior to multiple coats of varnish to protect the epoxy. All coats will have been applied by day's end today. It's 2PM and there is one more coat to apply. Weather perfect for this project today.
The 2nd coat of epoxy is squeeged on
The 3rd coat
Here you see my logo and you can also see the texture of the cloth through the 4 coats of epoxy. It looks lumpy but will be shiny and smooth when finished.
Here you can see the left side sanded and ready for varnish. Compare it to the un-sanded right side. The canoe is shiny and then sanded dull many times in the course of construction.
This shows the inside ready for sanding prior to glassing
Following sanding-still ugly
The sealer coat of epoxy is now on the inner hull. After curing it will be lightly sanded and then fiberglass cloth will be layered up with 2 coats of epoxy. using 2 coats makes the boat lighter in weight and allows for some texture on the inside to control slippage when getting in and out.
This is a little trick we discovered a while ago. Cutting a small piece of cloth to fit the stems, and lightly spraying the wood with an adhesive allows for pre-positioning of that part of the cloth. Each end is first fitted this way and then a long piece is added, making the ends much tidier.
Here we can see the rest of the cloth being fitted. Note the wrinkles prior to adding the epoxy.
After 2 coats of epoxy, the inside of the hull is now ready to add the decorative aspects. Decks, a backrest and the gunwales are yet to be added. I may use more cedar strips for the decks, building them first and then attaching them to the hull with epoxy and bias tape. It should be a nice, clean way to accomplish this step. Instead of the traditional thwart, I plan to build in a sturdy backrest that will also provide for a watertight compartment at the stern. We'll know how it comes out in a week or so - or a day or so - depending on stuff...
Work begins on the stern deck. This is longer than a regular canoe deck. It will be sealed to the gunwales and the interior of the hull to provide both storage space and flotation. The tape and clamps allow for the strips to be glued up without using any staples, leaving a cleaner look in the end.
These 2 pieces are for the bow deck and the facing piece to seal the bow into flotation space. They have been fiberglassed on what will be the inside of them. The outside is glassed after installation. A canoe would remain open, this little boat can stand a bit more flotation than normal because it's so small.
At the end of the day there are only a few more strips left to glue up for the stern deck. I should finish it on the next work day. I forgot to allow enough cloth for the long deck - inside and out, so another trip to the coast is in order on Monday to get that .
The stern deck is elongated on this boat and will double as a backrest. once the cross-member has been installed. That will be crafted from a waste ship's knee.
The bow deck includes an enclosed compartment which will provide a bit of flotation. I've decided not to enclose the stern deck as previously planned. Since I rarely tip a canoe over by accident I'll leave this open for quick retrieval of extra clothing, binoculars and cameras. The decks now have the sealer coat of epoxy applied. The next day will be a time to sand that and apply the woven glass cloth for strength.
Here you can see both decks, even though one is covered with sandbags and stuff. See the little viola blossom on the bow deck? Sandbags weight the deck assembly so it fits tight against the hull while the glue dries. The inwales are clamped on and waiting for glue to cure as well. Next step will be outwales and that completes the structural part of the boat; then multiple coats of varnish to protect it all and it's done.
The top-sides have 2 coats of varnish now- 4 more to go before the hull gets the 6 coats to protect it from the sun. At 1 coat per day it'll be ready when the water is
The painter line is attached and Viola's namesake visible here
Here you can see the walnut block as an attachment point for the high-tech seat I decided to use.
Here sits Viola, on the way to the pond for a dip. The Paddle is from Shaw & Tenney, an old established paddle and oar company in Orono Maine
The blade of my 9-foot double canoe paddle
Here sits Viola, in front of the perky little flowers that she's named for. When I began the canoe there was one lonesome blossom (the one that is now embedded in the bow deck). 3 weeks later just look at the riot of color they bring to the early spring garden in front of the house
May 3rd, 2007
Viola looks natural on the dock, nestled into the reeds left from last summer. This was a "soft" launch this morning, just to see if she would float. Not only did she float, but this little adaptation of Rushton's Wee Lassie goes like the wind on the water. I'm looking forward to the first excursion in real water instead of our little pond. I'm sure this will be one of my favorite boats