Step 1: Tools
Step 2: Supplies
2 2x2's (rib supports)
8 2x1's (floor structure)
Caulk 5200( THIS IS A MUST ITS EXPENSIVE BUT IS AS STRONG AS CEMENT AND WATERPROOF)
Caulk liquid nail ( this is used for the floor structure)
2" PVC 10ft pipe( mast)
1/2' PVC ( boom)
2" big screw/bolt (for attaching the wooden sides to the ribs)
4" long bolt and nut ( attaching the mast and boom)
hose tightner (the boom and mast)
10 right angles with bolts and washers and nuts
Step 3: Beginning
Cut up 3 2x2's into the length and beam of your boat apply caulk and let it dry for 3 days make sure to clamp it.
Step 4: Cutting the Ribs or the Structure of the Boat
I made a cardboard template and then traced the design onto the wood. And then cut out 8 identical ribs
its important to leave a space over the 2x2's so that they can be caulked on make sure the gap fits nice and snug.
You want the ribs to extend all the way up the sides of the walls so I mad mine 10 inches. I had a rib every foot or so.
Step 5: Attaching Sides
This is pretty simple but just make sure its nice and even. As seen below.
Drill pilot holes into the ribs 2 per rib. these are what the bolts are going to be screwed into
After drilling the holes apply 5200 over the ribs and socket wrench the sides on.
Step 6: Bending the Wood
After the sides have been placed on now is the hard part of bending the wood into its bow shape. If you've done everything right
then when you bend the sides and bow up words they should line up great and make a bow shape. Take the right angle pieces and drill pilot holes into the base and sides
then caulk and bolt the sides on I'd recommend 5 angles per side. There will be popping noises from the boat these are to be expected but be aware that the sides may crack
at the sloping part, mine did.
Step 7: Center Board Hole
I used the 2x10 again for the centerboard but planed it down to make it fit.
After finding the exact center and making sure the line is centered and straight, cut out the hole and mount your rudder board holder with the 5200 caulk
use more than you would elsewhere because this is a big step and messing up would be a pain at this step.
Step 8: The Floor
So take the 2x1's and create a "flooring" then caulk it on with the liquid nails caulk. After this cut up plywood pieces so they cover the 2x1's and create a false floor.
Step 9: Attaching Rear Piece
Step 10: Caulking
so it can come off.
Step 11: Attaching the "deck"
Step 12: Rudder
attached is also the rudder (with its half of the hinges) and the centerboard