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.