Monday, March 23, 2015

Shop updates 3-22-2015

We have had a full shop this winter, one of the busiest yet.  Lots of ongoing restorations, canoes being built, build your own canoe classes, and canoe paddles being made.  Almost all of the restorations have been large projects, not just simple recanvas jobs, but very detailed and complex work.  Lots of accoutrements too - originals to be repaired and refinished and replacements to be made - of paddles, oars, sail rigs, floor boards, seat backs, hardware, etc.

If you have ever thought about building your canoe, we would love to have you join one of our classes.  We are booking for our fall 2015 classes and winter 2016. Why not sign up now?  It is never too early. 

Waltham long deck courting canoe
The Waltham had a lot of rot throughout the decks, framing and inner rails. 
First step is to make and bend a pair of replacement inner rails. 

The inner rails are milled and planed to size......

.....then steam bent on the jigs.

While we wait for the rails to dry on the jigs, here is a look at the rotten damage.
Deck framing missing

Rotted out end

The other end, rotten and missing wood.
A look at the rotten inner rails.
Oh look at that, the inner rails are dry, off the jig and ready to install.
First the old ratty-tatty rails need to be removed very delicately.
The new rails going in
The new rails in
Ends and deck framing being rebuilt
New inner rails, ends rebuilt, and new deck framing.
A closer look at the deck framing
We even duplicated the notched inner rails-
the planking is notched into the inner rail
toward the end of the deck to give a very pleasing sheer curve.
This is a patented trademark of several Boston area canoe builders.
New canoe building
Emily cutting a rolling bevel on a stem
Ribs are bent on the Chicot form
Ribs being bent on the Smoothwater form
Chicot being planked up in the background.
Emily working on the Smoothwater.
Another shot
After hand clinching, the hull is wetted
to soak out the hammer blossoms
Emily getting the Chicot form ready for another canoe
Ribs are bent on the Chicot.
What is that in the background?
It's the little 1/2 scale model!
1/2 scale ready to be planked
Being planked
The size of the deck for the 1/2 scale
The 1/2 scale ready for finish.
These are built just like a full size canoe.
Bent ribs, hand fitted planking clinch fastened, canvas covered, etc.
Here is one of the 14' Smoothwaters being canvassed.
This one is the light weight version - should come in around 35 pounds.
Emily working on replacing ribs in the Brodbeck -
15 in a row
All the broken ribs replaced
The interior varnished - looking at the replacement ribs.
Can you tell the difference between the new and old?
Another look at the interior
The Brodbeck ready for canvas
The Brodbeck being canvassed
 Pictures from around the shop
A pretty familiar scene in the shop -
canoes every where in all sorts of stages of restoration.
The dinghy getting ready to be canvassed
The dinghy being canvassed
The white oak outer stem for the dinghy being bent

Outer rails being installed on the double ender
New seat backs being made from quarter sawn red spruce

 Ready for finish

More inner rails being steam bent
Old Town OTCA getting a new pair of mahogany outer gunwales
The 1905 Old Town canvased and filled
Not only fulfilling orders but getting ready for spring orders too
Part of a larger run of paddles being made here in the shop.
These are custom made and available for sale.
Contact us for more information.
Timber cat - the inspector.

  A view from our workbench. 

Monday, January 12, 2015

Shop updates 1-12-2015

We are often asked if we have enough work to keep us busy through the winter.  The answer is yes and then some.  We keep very busy year round but winter is usually one of our busiest times of the year - come spring and early summer is when everyone wants their canoes and boats. .

Work continues to go apace in the shop.  The sailing dinghy has moved along nicely, the Peterborough Admiral is finished, and other canoes and boats continue to be progressed forward.  We had several canoes which required inner gunwales to be replaced and lots of outer stems too.

We tore up our dust collection system, updated and moved it, and added some new machines.  The dust collector is now on the shop level and has a dust transfer component to it so we no longer have to handle the dust and shavings.

1930's OLD TOWN DINGHY continued
The new inner keel was steam bent on a jig. 
Here Emily has the keel removed and is
planning the rolling bevel on the underside.
More planning
The slot or mortise for the centerboard trunk is cut out
with a coping saw and finish with a chisel.
Test fitting the inner keel
Looks pretty good
Now that the inner keel is fastened in,
it is time for the inner stem.
First order of business is to make a pattern
so we can make an accurate jig for bending.
The new stem bent on the jig
The new blank next to the old stem
The bevel on the stem is put on completely by hand with a draw knife.
Above Dylan carefully shapes the rolling bevel along the sides
of the stem.
A view from the operators seat

Once the bevel has been established
the rib notches are cut with hand saw.....
......and chisel.
The new stem and inner keel installed.

Now that the new inner keel is made and installed
we can shift our attention to a new centerboard trunk.
Test fitting the trunk.
Before final assembly the trunk is sealed off on the inside.

Next is to make the floor boards.
Above, floor board stock awaiting.
Floorboards being laid out.

The dinghy with new inner gunwales, new inner keel,
new inner stem, replaced ribs and planking,
new centerboard trunk,and new floor boards. 
Ready for the finish room for some varnish.

We tore up part of the shop and updated the dust
collection system.  It looked like a bomb went off
for a few weeks.....
....but is up and running and working like a charm.
It kind of looks like Dr. Octopus from Spider-Man
 but there is no more handling the dust, shavings, wood chips.
The dust is sucked up at each machine, goes through the cyclone,
and drops through a rotary airlock into a transfer blower
that blows the dust into a huge 14x8x8 bin.
Two Old Town's getting their inner gunwales replaced.
One with Mahogany, the other spruce.

Ribs being bent around the hull for replacement.
A look at the damaged interior of the Brodbeck.
The ribs marked with blue indicate those that
are damaged and will be replaced.
An Old Town ready for the finish room - new inner gunwales,
a dozen new ribs, some planking, rebuilt ends, etc.
An interesting project we were commissioned for.
A set of Adirondack chairs built to our own design.
More on this later, perhaps in its' own post, but for now
here is the new workbench we are working on. 
It will be a traditional cabinet makers bench with tail vise
and front vise.  The top is made from4 inch thick solid maple. 
The base will be solid hard maple mortised and tenoned together.
Here the underside is being flattened by hand.
The Admiral is finished,wrapped, and in storage for the winter.
We'll put up some finished pictures in the spring.

Until the next post, if we don't see you through the week
we'll see you through window.