How to build a wooden boat

Many people had tried to convince us that wooden boats are hard to build. Our “renovation” of Mahdee has been described by others as a complete rebuild. Therefore, I consider myself almost an experienced wooden boat builder. It really isn’t that hard, so I have decided to distill everything I now know about wooden boats into an 8-step how-to.

Step 1: Buy lots and lots of big boards/timbers. Big is key here. If it takes 6 grown men or a crane to lift one board, you are on the right track. You will want several types of wood and the types should be the most exotic possible even if that means spending lots of money. We all know how important bragging rights are if you are stranded in a yacht club some day.

Step 2: Cut up all the boards/timbers into little pieces. If your neighbors accuse you of operating a toothpick factory you are on the right track. Of course, some pieces will be bigger than toothpicks, but they will be in the minority and the casual observer probably won’t notice them.

Step 3: Drill lots of holes in your pieces of boards. The more the better, and the holes should be of various sizes from barely visible to … well the biggest size will be limited by how thorough you were in step 2.

Step 4: Assemble the parts.

Step 5: Try to plug all the seams between the pieces made in step 2.

Step 6: Try to find and plug all of the holes drilled in step 3. If you think you have them all, drill some more holes, wait a few months and then see if you can find them. There must be way more holes than you can comprehend.

Step 7: Put boat in water and look for leaks caused by failure to complete steps 5 and 6.

Step 8: Have fun. This is the most important step because the whole purpose of owning a wooden boat is to enjoy it!

The good side of dread

I know that everyone is seeing dread as a negative thing. I think that there is also a good side of dread. Occasionally I jump into a project and later I realize that I was not prepared and made some decisions with consequences that were not fully appreciated during execution. Dread functions to keep the project from starting until some later time. As a result, there is time to consider all, or many of the possible paths a project could follow. Usually there are many more paths that lead to bad outcomes and only one or a few that are really good.

For example, in drilling a hole, I can consider the various consequences of the hole veering off in various directions. Some of those consequences are really, really bad. Some are not so bad, or have subsequent fixes that can mediate the consequences of the error. So when it comes time to drill the hole, I want to make sure that there is no veering in the directions with really bad consequences, and if the hole isn’t to be perfect (and holes rarely are in real life), it veers in directions that have low consequences.

Unfortunately, my natural tendency is towards procrastination and dread becomes a useful excuse for not moving forward. The trick to a good project is to keep things moving forward and that requires multitasking the dread on many pieces of the project so that dread is overcome on pieces fast enough to keep everyone busy. The reward, however, is seeing Mahdee coming together in many different ways and knowing that each piece of her is well executed.

More milestones

Big news–the toilet is no longer sitting in the middle of Mahdee at the site of the future galley. Oh, and the engine stringers are installed. The latter being more significant, but the first seems to be having a bigger impact. Probably about 15 months ago we needed to move the toilet in order to make the new frames and floors under it. I argued that we should just move the big porcelain skipper with the attached plywood sole about 10 feet forward which would be out of the way while we did our work and wouldn’t require hefting it up and out of Mahdee and down the scaffolding and thence to some out of the way storage location in the boat yard (which didn’t really exist).

I took some ribbing by workers who had to go around or move the toilet a foot or two to do their work in Mahdee. Some of those complaining where even more irritated by other items stored outside Mahdee which I would point out to them. It seems there is never enough room. Back to the story, around 14 months ago we had the floor and frames done. In that part of the boat, however, Mahdee has several floor beams stacked on top of one another and 14 months ago only the bottom floor beam was installed. The super floors (as I like to call the overlying floor beams) have a primary purpose to provide support for the engine stringers.

The ends of those super floors extend out under the toilet and provide support for the sole in the head. In some locations around the engine we have three layers of floors, in particular, those near the head. Today, I finally got all of those layers of floors finished and installed. The engine stringers look great to me, but the real fun was moving the toilet back into its place of honor. Coinciding with that occasion, Ryder has finished a comprehensive cleaning of the inside of the boat, so the interior looks really big and uncluttered.

Because of all the cleaning, I have had to confine my dust making work to places outside the hull. Early work on the floors and stringers, before the dust ban, required lots of cutting, re-cutting, grinding and sanding to make everything fit. The result was, in John’s words, “a purple haze” in the boat due to the use of purple heart as the dominant structural wood. All this while John was accused of making too much dust. He was choking down buckets of Sapele dust while rough faring the planks on the hull. Anyway, after the dust ban inside Mahdee came into full force, I finished the last two super floors which miraculously fit perfectly the first time. Must have been the motivation to not climb into and out of the boat 10 times to make little cuts and grinds to fine tune the fit. On the other hand, maybe all the practice on the previous floors culminated in perfect skill. That thought occurred to me and then I broke two 5″ bronze fasteners inside the second “perfect” super-floor while trying to attach it to the boat. This served to re-humble me.

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