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7 • Depending on the style of deck to be installed, the inwales need trim- ming for a proper fit. I chose a com- promise between simplicity and looks. My decks sit flush with the inside of the hull and the outwale, their bases butting up against the inwales. These look good and are strong enough to double as handles. I cut the inwales just inside the tip of the canoe, trim- ming them to size later.


8 • I repeated the clamping and inwale-trimming process working from the center to the other end of the canoe. This is a good time to take a step back and check to ensure the lines of the new rails look right and adjust the clamps as necessary.


At this point, I realized my new gunwales didn’t cover the holes created by the fastening of the old trim. The aluminum trim I removed was one inch tall, so I had to trim down the hull of the canoe slightly to accom- modate the new gunwales. I traced the new gunwales at the required height, masked off the line and used a rotary tool to trim down the hull. Be sure to wear eye protection, gloves and a mask as dust from composite hulls is harmful.


9 • Wood gunwales should be screwed together every six inches. For strength, it’s best to make new holes rather than trying to reuse the old ones. Start- ing halfway between the old holes as close to center as possible, I marked the new screw locations on the inwales working towards each end. Because I had to screw from the exterior near the ends, I made the last few marks on the outwales. My decks are mounted with three screws on each side, requiring holes at the ends to be closer together.


10 • Again, starting from center, using the 11/64-inch tapered bit and #8 countersink, I predrilled holes through the inwale, hull and into the outwale and vice versa for the last couple of holes before the decks on each end where it was impossible to drill from the interior. Do not predrill holes for the decks yet. Set the bit in the drill so as not to drill all the way through. Also, make sure the holes are low enough to penetrate the hull so the gunwales hold on.


60 SPRING 2013


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