Tampilkan postingan dengan label deck. Tampilkan semua postingan
Tampilkan postingan dengan label deck. Tampilkan semua postingan

Rabu, 23 November 2016

Stacking the Deck

The first step in the deck planking process was laying out the lines on the subdeck plywood so I could figure out what wood I needed to do the job. I drew in a 2" grid pattern on the sub-deck to ensure that the center planking would be symetrical. Using a batten, I drew in the perimeter cover board lines to follow the carlings aft of the dash and stay a "constant distance off the shear line" forward of the dash. I made the first line drawn on the forward deck (that I liked) the "master" and copied it to the other side. There is a slight difference in distance to the shear line from one side to the other, but not enough to worry about.





Then a trip to Armstong millworks to buy some African Mohoghany for the deck planking and then learn how to re-saw. The guys at Armstrong suggested that starting with 4/4 stock planed to as thick as possible (about .90") would be the best approach.









I started with laying out the boards along one side of the boat to determine joint locations to get a 12 long 10" wide board to cover the width and length. Due to the limitations of my shop, the board was cut into the pieces and angles necessary to go around the boat on one side, then each piece re-sawn to create the piece for the opposite side. With a riser kit previously installed on my bandsaw, a new 1/2" wide skip tooth blade, new Olsen "cool blocks" and a 6" tall fence, I started bandsawing the wood for the outer perimeter planking. The piece at the back of the boat was 9 3/4" wide and the re-saw went very, very, slowly, but it worked. Then a few trips through the thickness planer (new blades installed) yielded planks about .34" thick. Using countersunk screws, the first piece was located, beginning at the aft end of the boat and working forward, a joint line established, chop cut on the mitre saw, reinstalled and the next piece cut to fit up against the previous piece.
After the joints were established, the inside line location was transferred from the sub-deck to the underside of the cover boards. In the cockpit and motor opening area, tracing on the underside was straightforward. In other areas the grid pattern was used to re-create the line by tracing the inside edge of the boards onto the grid pattern and measuring to the line intersection at each grid line. Tedious, but it worked. Line was cut on the bandsaw about 1/32" proud and then sanded to the line with a small 1" stationary belt sander. Outer lines were traced, cut, and sanded in a similar manner.

The kingplank down the middle of the boat took a bit of trial and error to find a width that looked "right". I started at 6 1/2" wide, about an inch wider than the perimeter boards in the fore deck area and it seemed too dominant. At 5 1/2" it still seemed too wide, so eventually my aesthetic director concurred with a 4" wide being the "right" width.

The grid pattern helped with cyphering out the width of the longitudinal planks. Eventually settling on 1 7/8" width, and a 3/16" gap. In order to fully utilize the boards I had purchased and not have to go buy more wood, I needed to squeeze four planks from a board width of just under 7 3/4" inch. (Maybe the king plank should have been a bit wider!) This created an opportunity to buy a new tool for the shop - a micro-kerf table saw blade which only cuts a 1/16" wide kerf. After creating a new table saw zero-clearance insert with a splitter, I was all set to cut the planks. The new blade cut like butter and I got all the pieces needed to cover the deck.



The plan at the moment is to stain the perimeter and king planks a darker color to provide greater contrast. Then finish all the planks to seal all the grain and complete the deck using a white pigmented epoxy to fill the gaps.


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Jumat, 16 September 2016

Shall I Cut the Deck

My plan is to get the boat out of the basement before putting on the deck plywood so it will be somewhat easier to handle and slightly lighter. But, there isnt any reason not to go ahead with doing the rough cutting and fitting. After a bit of sketching of how to cut the pieces, it seemed the only way to get the front deck pieces out of one sheet of plywood was to use the factory edge down the centerline of the boat starting about 18" in from the end. The opposite side piece would use the other side of the sheet but the sheet would be flipped over to fit the mirror image piece. I plan on having a natural wood finish on the deck using just the plywood but with a paint graphic band down the center to hind the seam. Luckily, the plywood has veneer that looks very similar in grain and color on both sides of the sheet. The first sheet of deck plywood is not supposed to stop at the dash or any frame, but continue as far as possible along the carling and sheer as not to create a weak spot. After positioning the full sheet down the centerline of the boat and clamping it in place, a line was traced on the underneath side to show where to cut it. A 1/4" thick scrap piece was used to offset the pencil mark to allow at least a 1/4" overhang at all edges. Then the sheet was taken off the boat and set up in my shop for cutting with a jig saw. I quit for the day at that point to sleep on it before cutting.






Some blue tape was put beside the cut line which minimized any tear out of the veneer and helped visualize the line to be cut. The firse piece went well as did the second. Putting them both on the boat confirmed that the color and grain look very similar between the two halves.


The next task was the back halves. The first one was marked and was left overnight just in case there was something I was overlooking. Nope, cut it and it fit. Tried it on the other side and it fit there too. So I used it as a pattern for the other side. I left overlaps between the front and back pieces to give me some adjustment when finally glued and attached.
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Selasa, 19 Juli 2016

Rear Deck Boards

A while back I made some templates for the back decks from the temporary working decks Ive had since 6th July 2010


I took these to a local firm that make ply lining for vans.  The have a couple of CNC router decks.  From these templates they digitised then cut the Wisadeck panels.  This board is difficult to cut as it splinters very easily if cut with a saw.   


The router cuts a nice clean square edge and the curve is nice and continious.  The edges were then beautiflly painted and sealed by SWMBO.
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Minggu, 12 Juni 2016

Deck Staining

When we put in a patio I thought I would never have to stain a deck again.... After hand sanding all the deck surfaces with 220 grit, some vacumming, wipe down and room clean-up it was time to mask and stain. A bit of blue tape, plastic and masking paper and I was ready to have at it.
After staining everything, there were some blothy spots around one of the perimeter planking joints and a couple of sanding scratches on that same side. After letting it sit overnight, I still was not satisfied with those areas. So I hand sanded again with 220 grit one whole side, cleaned it up and restained. Its good enough now to move on. Looks pretty cool even if I say so myself.
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Kamis, 21 April 2016

All Hands on Deck

The next task in the deck planking was to fit and epoxy down all the longitudinal planks. Beginning at the center king plank, I worked my way outward fitting and "clamping" each board in place using 3/16" fender washers with #8 round head sheet metal screws 3/4" long. I used the grid lines already on the subdeck to establish hold downs every 4" along each plank. A pilot hole was drilled prior to putting in a screw. Where the leading edge of a plank mated to the perimeter cover boards, a rough angle cut was made on the chop saw or band saw. Then holding the plank in place, a final line was marked using a spacer. I sanded to the line on my 1" stationary belt sander. (Actual work took a lot longer than writing about it.)

A box of 100 washers allowed me to get two or three rows done on each side of the boat at a time. I used pieces of luan plywood as spacers which happen to measure 3/16" thick. Once I had a batch ready to go, all screws were removed and the unthickened epoxy spread on the subdeck areas to be glued and the underneath side of each plank. Then thickened epoxy was spread on each plank and the plank put in place. The washer/screws were hand started and then beginning at the forward end, spacers put in place and the screws tightened to lock the plank in place.

After a set of planks were fit and screws tightened, the spacers were removed so they wouldnt get bonded in place. I put in some 3/16" tile spacers just to make sure nothing moved, but they were not necessary. After the epoxy set overnight, the screws and washers were removed. Any washer that stuck to the wood was unstuck with a chisel. I put the rounded edge of the spacer towards the wood to reduce the chance of marking the wood and helping with removal if stuck.

The process was tedious and my shoulder hurt at times from holding the cordless screwdriver, but seeing the deck transform from boring to way cool was worth all the fuss. It took four days of work but Im ready to move on to the next step if I can figure out what that is. On the last day of epoxy work I made some sample boards with planking scraps so I can experiment with staining, finishing, and gap filling.

However, I have a few more screws to remove first.
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Senin, 16 Maret 2015

Jon boat front deck plans

Jon boat front deck plans Some images on Jon boat front deck plans Jon Boat Casting Deck Flat Bottom Jon Boat Plans Wood Patio Deck Design Deck Designs and Plans Grizzly Jon Boats
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