Lazy weekend Canoe 2.0 Build
of Material and Hints and Tips
Bill of Material
(3) sheets of 1/4" ACX or marine plywood
(1) 16' to 20' 2x8, 10, or 12 (or shorter, if you don't mind scarfing)
(200-300) #6 3/4" stainless steel screws
(8) 2" stainless steel or corrosion resistant screws
(2) tubes of PL Premium or a quart of TiteBond III - does not need
epoxy
(1) tube of exterior, paintable caulk.
(more than 1) quart of paint or varnish
Brushes and such
Recommended Tools
Circular saw with guide - for ripping 1x2s from the 2x material
and cutting sides/seats
Table saw - for shaping the stems (or ripping 1x2s)
Saber saw - for cutting plywood parts
Hand saw or flush cut saw - for trimming stems
Chop saw - for cutting frame pieces
Router with 1/4"or 3/8" roundover bit
Power planer - though a hand planer or belt sander with coarse paper
will work, too.
Orbital sander
Powered screw driver with bit for the screws listed above
1/8" drill bit for pilot holes
Hints and Tips
This project is so easy it can be done in a lazy weekend. With effort,
a person can go from unloading the lumber to having a paintable
boat in about 12 hours, but that's working hard.
Plywood:
Regular, cheap-o 1/4" ACX or even 5mm underlayment is fine,
so long as it is rated for exterior use, it'll work just fine.
Timbers:
The chines and gunnels need to be fairly knot-free, the stress of
the bend will cause them to break.
The thwarts need to be fairly knot-free as they become the seat
supports and have to hold up your weight.
The stems and frame arms can be fairly well riddled with knots.
The most cost effective way to get knot-free timbers is to rip
them from 2x material - wider lumber usually has fewer knots, just
pick through the pile until you find a board you like. I recommend
going for a 20' 2x12 just to save the hassle of scarfing.
Assembly
When working quickly, I usually use 1", coarse thread, drywall
screws with fender washers to hold the butt-joints while the glue
cures. This way, I can be building while the glue cures.
Once the glue has cured, remove the screws and fill the holes with
round toothpicks dipped in glue. Once that glue has cured, slice
off the bits of toothpick that are sticking out.
If you don't want the middle seat, you can just use screws to hold
the center frames in place during assembly. Once the chines and
gunnels are on, you can remove the center frames and the boat will
still hold it's shape.
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