Nautical Research Journal 223
33. Moldings and trim rails.
32. T e deck in place, masked for future gluing where necessary and fi nish painted.
T e decks were 1/16-inch birch plywood over sawed deck beams; kerf-bent supports were epoxied to the inside of the hull at the sheer line to give extra gluing surface (Figure 31) and the decks bonded to them and the beams with 30-minute epoxy. Determining the deck beam camber was fairly easy. I assumed the deck to have a constant radius crown and we had measured the rise (h) and a chord length (C) at one point inside the cabin using a straight batten and a tape measure. T e radius (R) of a curve, knowing those two dimensions, is given by this formula: R = h/2 + C2
/8h.
Gluing down the deck was tricky. I masked off the hull at the sheer line to keep epoxy squeeze-out off the outside of the hull itself and I cut the plywood a little oversize to allow for error when fi nally placing it. T e 30-minute epoxy I used was thickened a little with a fi ller to keep it from sagging and I applied a fairly generous amount to the beams and edge supports. T e plywood itself was laid in place, bent to the deck crown, and held down with masking tape until the epoxy set. I used lots of tape to ensure I had good contact all the way around the sheer line.
Once everything had set I sanded the edges of the plywood fl ush with the hull and began painting it. T e original boat had a canvassed deck that appeared perfectly smooth. I masked off areas where other parts would need bonding and applied several coats of white primer, sanding between coats, to fi ll the pores in the wood. T e deck’s actual color was a
34.T e caps at the ends of the cabin sides.
35. T e set up for making consistent dadoes in longer stock.
poser because the museum’s lighting made it nearly impossible to ascertain the real color. However, Burger supplied the name of the gentleman who did the paintwork during the restoration and Scottie Dayton, from Manitowoc and once the editor of this magazine, found that he still worked in the area and put me in contact with him. He told us that the paint was a standard marine paint, “Sundown Buff ” from Interlux, applied right out of the can with no color mixing. Badger “Salmon Buff ”, #16-427, was an almost perfect match. (Figure 32)
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