Big wooden boat project [Splashed Sept 2017]

thomas15

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Ned
Great story and fantastic work. Your project thread reminds me of when I was a kid. My Dad built two boats and my brother and me kind of helped along. We lived in Belmar NJ and Hubert boats were somewhat common. My Dad knew some folks at Hubert and spoke highly of them. For about 10 years from mid 1950s to 1960s Dad and Grandpop were large scale (for the time) commercial fishermen and ran their boat out of Pt. Pleasant so they knew everyone in the boat building business on the shore.

There was a lumber yard in what is now called Ocean Twp NJ, just north of the Asbury Park circle in Rt 35., not sure of the spelling but we pronounced it Deku Lumber. They sold a lot of marine lumber and did a lot of milling and planning. When we picked up lumber the owner had many stories of backyard boat builders that he would speak of. I remember huge high drafts of lumber there, the very loud sound of the planner and the aroma of the lumber. We used a lot of Weldwood resin glue also. Memories of Dad mixing up a batch.

One of our boats was a 14' skiff using the same lapstrake and Jersey cedar as your boat. Smaller our was obviously. I remember spending days/weeks peening over the copper rivet heads by hand. When it was done and painted on the inside you could see long rows of WWWWWWW patterns of the rivet/washer heads, probably 5 or so rows of these rivets the entire length of the boat. It really was an interesting design. To this day every time I pick up a ball peen hammer I think about all of those rivets. I was about 11-12 years old then. One of the amazing things about the experience was that my Dad used hand tools mostly, the only power tools were a twist bit drill, skill saw and a saber saw. We used hand planes, chisels and a brace and bit to drive the brass screws in. I still have most of his hand tools and clamps but none of the power tools have survived father time.

I remember one of my friends trying to tell my Dad about the virtues of fiberglass boats. The thing that has stuck in my head after all these years is my Dad informing my friend that under all that resin is a lot of wood.

Ned keep up the good work. I have some idea of all the work this has been for you. I wish I had your gumption!
 
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Ned L

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Thanks Thomas. It's great to hear about your memories of the shore. This Hubert Johnson actually spent many years in Belmar. I also spent some time commercial fishing out of Pt Pleasant.
It's great that you still have some of your dad's tools, those are things to hang on to. Hope you hang around to see her hit the water.
 

thomas15

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Aug 13, 2014
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Ned, the design of your boat was popular in the 60s and 70s in Belmar. Of course many wood hulls back then. We lived within sight of the marine basin and as kids would hang out at the docks and/or launch ramp. Did a lot of fishing from the bulkhead, there were times when half my class was there fishing. This is an experience that my kids never had which is sad.

I will be watching your activities and following your rebuild and look forward to the day when it hits the water. One of these days as my schedule eases up I'm going to do a resto project. I don't think it will be anywhere as ambitious as yours, I live in NE PA now and we have only lakes here. I would like to do something hefty enough for the bays and ocean.

I need to amend one of my previous comments, my Dad and Grandpop fished out of Pt. Pleasant from 1950 to 1959. Their boat was a retired Coast Guard vessel (CG 83-417) that they converted to a stern trawler. It was big enough (83') to spend a week off The Long Island Sound. During WW2 that boat in Coast Guard Service took part in the Normandy Invasion and spent many months in the Mediterranean Sea. My Dad did a good portion of the conversion from government service to fishing rig. The skiff I mentioned was based on a similar boat that they had on the trawler from time to time, until it was stolen from the boat yard.

I know that I'm going off the reservation with all this but one last comment. Our skiff had initially a 5.4 HP Evinrude Zepher (1948), which you know ..... slow. After some time a friend gave us a Evinrude Fastwin (1952) 14 HP which was one huge improvement. But my brother and I pined for more power. One day we were browsing in a boat yard down by Brick or Toms River and spotted a skiff very similar to our homemade one. It had a 35 HP Merc which just captured our imaginations. On inspection of the boat we noticed a Mfg, tag. That boat was made by Hubert Johnson. It is possible that they made the skiff that was stolen but I don't remember my dad saying anything about it. I also cannot say for sure that they (my Dad and Grandpop) had their trawler at Johnsons but I'm fairly sure they did
 
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Ned L

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Sep 17, 2008
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Oh I don't mind these drifts at all. I grew up very similarly, except for me it was up on the Navesink & Shrewsbury Rivers. I grew up much more familiar with names like Luhrs, Pedersen, Olsen, Zuback, Kulas, Zobel's, but was very familiar with Morton Johnson, Hubert Johnson, Johnson Brothers, Bayhead skiffs, Hankins and the like. It is a shame there aren't many of the lapstrake Jersey sea skiffs still around. There are a few, but you have to know where to find them. It really is because this boat is a true 'classic' Jersey sea skiff that I even considered taking her on. If she was a Chris Craft sea skiff I would not have given her even a second look (though the C.C.'s were good boats). I have a passion for the Jersey built boats, and have even given some presentations on the history of the boats and the builders.
 

Ned L

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We had some nice weather a week or so ago, so I took the opportunity pull back the curtain for a bit of fresh air while sanding. About the first time in a year and a half she could almost be seen.

ry%3D400



I have since finished painting the trunk cabin sides and windshield (white) and the cabin top ( 'Miami Tan'). It's getting close to time to start in on the hull.
 

Ned L

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And finally finished painting & varnishing on the trunk cabin.

ry%3D400
 

Ned L

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Thanks WOG. Not a 'show quality' paint job, it's what I would call respectable though. it's not easy trying to a real good paint job working under that dusty tarp & working around the framing for it. I figure it is only the surface, and next year it will be better with the next coat. (There does have to be a point where I say 'good enough' on things like the surface finish on the third coat of paint, or else it will never see the water.)
 

sphelps

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Looks great ! I like the Miami Tan color ... Should go great with the stained wood ....
 

Ned L

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Now that the end may be coming (for this year) it is time to turn to some things I decided need addressing on the bottom.
The starboard rudder backing block was pretty bad off, and the oak beam for the upper rudder bearing was badly checked where the rudder post and bearing pass though so it was time to replace both those.

Now this is not an easy place to get to. There is access to the bilge through the lazarette hatch and (on the starboard side only) a small access hatch cut in the cockpit sole. Thought the lazarette hatch you have about 7" of working space between the top of the stringer and the cockpit sole framing. Pretty much a you can't reach there from here sort of problem.

So, with careful work I got the rudder, two bell cranks, the stuffing box and upper bearing all taken apart and removed. And was left with this on the inside .

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Here you are looking at the starboard exhaust (large) and the cockpit scupper (small) where they pass though the transom. (And the end of the 2x10 oak beam that carries the upper rudder bearing. Here I have cut about 3 feet of the end and cut an 8:1 tapered scarf on the end.)

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Here is where the rudder passes through the bottom of the boat

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The bronze carriage bolts for the stuffing box look fine -- not bad for 58 year old bolts.

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Here is the original stuffing box (again, ... not bad looking for 58 yrs) along with the new mahogany backing block in place.

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Here the new 3ft length of white oak 1 1/2 x 10 is being glued in place.

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Things are a bit cramped in there!

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The next day take off the clamps.

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and clean the glue up a bit

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And some fresh gray paint while I'm there.

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Finally, mounting the upper bearing. The reach was that long in the very corner of the small access hatch that a 'normal' electric drill and bit wouldn't fit vertically in the corner so I used a brace and bit to drill one bearing bolt hole. It has a much longer reach and fits much tighter in the corner. --- Worded just fine.

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Next I moved on to ten new keel bolts, ......... first job there is to get the boat off her keel so I could pull the old worm shoe and get to the bottom of the keel.
 

nurseman

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Again, excellent as always. Just as a random question, do you happen to watch any of the "Tips from a Shipwright" videos on youtube? Louis Sauzedde is the guys name, and he does wooden boat work as well. Lots of good stuff from both of you!
 

Ned L

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Thank you!
.... I have seen a couple of his videos. He certainly is knowledgable and has some good ideas. I have felt that at times some of his methods are developed a bit more around a philosophy of 'gotta get it done',...which is what you need if someone is paying you for your work. I am fortunate in that because I am doing this for myself I can 'afford' to take a bit more of a traditional approach when in similar situations.
For instance,in the end I will have used barely a gallon of epoxy in this whole rebuild,.. he doesn't seem to hesitate to use epoxy in different forms.
 

Ned L

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Another interesting find as I work along, .......... The boat was built by the "Hubert S. Johnson boat works", and at least this one steering bell crank was cast by and purchased from the "Johnson Brothers Boat works". They were a competing builder very near by.

ry%3D400
 

Ned L

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Getting to replacing the 60 yr old keel bolts first involves getting the boat blocked up off the keel so that the worm shoe can be removed and the bottom of the keel exposed. Lots of cribbing, a couple of jacks, and some careful jacking and blocking and she is all set.

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Thee are 14 keel bolts in all, ranging from about 5 long up forward to 17" long aft (she has a pretty good size keel).

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the first bolt really didn't look bad.


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I took it to the wire wheel and it still looked pretty good.

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............ Except the color looked a little off for silicon bronze.

So I to a file to it,..........The color was definitely to 'red', and it filed too easily. When I got a good ways into it the color changed to a proper, more 'gold' color. A couple of hits with a hammer confirmed things.


ry%3D400


The outer 20% or so was shot and just scaled off (corrosion had left just the copper).

Even in this condition there was more than enough strength remaining in them, however this corrosion was also in the area of the threads, so even though the bolts had good strength left the nuts on top could not bite onto good material. The threads did actually pull off a couple of bolts that I tried to tighten.

The decision was made. ..... I had already also bought the materials, (15 feet of new 1/2" silicon bronze bar stock and 25 new 1/2 x 13 bronze nuts).

The process was to remove the nut and washer from the inside, use a 15 lb mall and 1/2 steel rod to drive out the old keel bolt, go to the garage to cut a new length about 1/2" longer,

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thread both ends

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apply some high strength "Loctite",

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tighten the nut on the bottom end, and peen the end of the threads over with a ball peen hammer.

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I have had a 6 ft piece of 1/4" 2" copper bus bar laying around for years. I decided this was finally good use for it.

I cut it into 2"x2" squares and drilled 1/2" holes on center. They make pretty hefty washers.

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When a bolt was made it was time to take it out to the boat. A good layer of roofing tar (yep, ... roofing tar)

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And it is ready to put in place.

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Then the new square washer, the old round washer and the new nut get added.

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Ned L

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I was able to get to, and replace 10 of the 14 bolts. I was lucky in that I could get to the tops of another three, where I replaced the nuts and the threads are still holding on well. Things are now definitely in good condition and could last another 60 years.

the last part of the job was to make up and install a new worm shoe.

Get out a piece of white oak (it's what I have, usually only something like red oak is used here).

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A little milling and I have the needed pieces.

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Usually a worm shoe is simply a flat piece, but I saw this done about 40 years ago at a boatyard where we had the keel bolts replaced on our family boat, and I like the idea. Cutting it like this actually cradles the bottom of the keel and gives better protection.

Cut some strips of roofing felt (tar paper) to lay in the 'trough'

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lay them in and cover with a generous layer of roofing cement and they are set to nail to the bottom of the keel.

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Ok, .... so some may be wondering "what is a worm shoe?" ........... In warm water environments (traditionally from about the Carolinas and south, but recently moving into the N.E.) there are marine borer worms that bore into and eat wood in salt water environments (kind of like earth worms in dirt). These marine borers can actually turn large wood timbers into nothing more than Swiss cheese, full of tunneled holes within a fairly short period of time. They cannot get into wood that is covered with bottom paint. However in places where bottom paint is worn off down to bare wood this provides an entry point where the worms can bore into the wood and start their damage.
[FONT=&quot] Because the bottom of the keel is a likely place for bottom paint to get worn off of, a protective (expendable) piece of wood is nailed to the bottom. It is called a worm shoe. -- one important part of the installation is to lay a layer of roofing felt between the two, so that if worms get into the worm shoe they can not move up to the keel[/FONT]
 
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sphelps

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Nov 16, 2011
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Thanks Ned ! I just got roofing bull on me somehow !! :lol: Ya had to open the can !
Very impressive stuff as usual !
 

mxcobra

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Jun 27, 2011
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I have been watching this project, figured I better make myself known. What a cool boat you have their
 

bobkat1864

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Apr 1, 2012
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Nice work, Ned. I am a wooden boat owner myself..(1979 Skiffcraft 26) and I have been following your project with great interest since you began. Thanks so much for sharing.
 
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