Pete McMiller
Well-known member
So, let's build a Devlin Poleboat. I've wanted a new skiff for a while now - my Kara just isn't as versitile as I wanted and the Poleboat seems like it will do the job I need it for. The only difficulty with the Poleboat is that, according to the plans, it weighs 95 lbs. and might even go higher than that. Too heavy for me so I am going to build this with weight in mind. To start with, I am using 4mm Okume instead of the specified 6mm. That should help some. Also I am going to use Sitka spruce shear clamps. I'm also going to use less glass and epoxy than is specified - yep I know I'm taking a chance with the finished integrity but I need to know how well this will work. I have 3.25 oz tight weave cloth from RAKA and 4" x 6 oz. tape for the seams. I'm going to show quite a few extra pics for those how want to build a boat but don't know where to start or the steps involved.
OK, this pic is just setting up the plywood for scarfing. I used a 10:1 ratio rather than a typical 8:1 just because of the thickness of the plywood.
I used a borrowed belt sander with a 40 grit belt to cut it down.
I think total time was about 45 minutes
I clamped all four pieces (two scarf joints) at the same time with visqueen between the layers and also top/bottom.
Rolling epoxy station. I covered the top with visqueen - just makes clean up so much easier.
I used a little too much epoxy so had to sand the joints down the next day.
panels cut out after lofting. I stacked the panels on top of each other to make cutting out easier.
Edges planed even and fair.
stitching together. I used 18 ga. wire as the panels are only 4mm I didn't want big honking wire busting through when I tightened them. This is actually the second time I stitched it - the first time I used a 1/4" drill bit for spacing and then couldn't open the panels up - too tight. This spacing seemed to work pretty good though I had to tighten a few of them after it was all open.
These next three are various phases of stitching the shear panels on. I had originally thought I could build this without forms but the 4mm is so flimsy that there was no way to do it and still retain the proper shape of the hull. The forms themselves didn't take too long to construct.
Last pic for today. Keel and chine inside fillets are done and cured.
At the moment I am working on the foreward and aft bulkheads as well as the amidship knees. I hope to be able to epoxy them either today or tomorrow.
OK, this pic is just setting up the plywood for scarfing. I used a 10:1 ratio rather than a typical 8:1 just because of the thickness of the plywood.
I used a borrowed belt sander with a 40 grit belt to cut it down.
I think total time was about 45 minutes
I clamped all four pieces (two scarf joints) at the same time with visqueen between the layers and also top/bottom.
Rolling epoxy station. I covered the top with visqueen - just makes clean up so much easier.
I used a little too much epoxy so had to sand the joints down the next day.
panels cut out after lofting. I stacked the panels on top of each other to make cutting out easier.
Edges planed even and fair.
stitching together. I used 18 ga. wire as the panels are only 4mm I didn't want big honking wire busting through when I tightened them. This is actually the second time I stitched it - the first time I used a 1/4" drill bit for spacing and then couldn't open the panels up - too tight. This spacing seemed to work pretty good though I had to tighten a few of them after it was all open.
These next three are various phases of stitching the shear panels on. I had originally thought I could build this without forms but the 4mm is so flimsy that there was no way to do it and still retain the proper shape of the hull. The forms themselves didn't take too long to construct.
Last pic for today. Keel and chine inside fillets are done and cured.
At the moment I am working on the foreward and aft bulkheads as well as the amidship knees. I hope to be able to epoxy them either today or tomorrow.
