Jim Michalak's Boat Designs
1024 Merrill St, Lebanon, IL 62254
A page of boat designs and essays.
(15 September 2017) We will review butt joints. The 1 October issue will take a sail in OliveOly.
TIME FOR THE INDIANA MESSABOUT!
Fellow Messers,
July 4th is behind us and mid-September is closing fast. We just wanted to send a short reminder that the 26th occurrence of the Lake Monroe Midwest Messabout will be September 15, 16, & 17 -- mark your calendars.
Go to https://sites.google.com/site/lakemonroemidwestmessabout/home for additional information and feel free to drop us a line if you have any questions. If you're planning to attend, and want us to add your name/boat/homeport to the website's "Who's Coming" list just send us an email.
Hope to see all of you in just a few weeks. We have the ice cream maker standing by!! Pass the word to all your boating friends. Regards, John & Susan McDaniel
THE BOOK IS OUT!
BOATBUILDING FOR BEGINNERS (AND BEYOND)
is out now, written by me and edited by Garth Battista of Breakaway Books. You might find it at your bookstore. If not check it out at the....ON LINE CATALOG OF MY PLANS...
...which can now be found at Duckworks Magazine. You order with a shopping cart set up and pay with credit cards or by Paypal. Then Duckworks sends me an email about the order and then I send the plans right from me to you.
 | Left:
A pair of twelve footers, a Mayfly12 and a Skat, sail at Lake Stockton. |
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Butt Joints In Plywood
BACKGROUND...
Almost any boat you build from plywood will require panels longer than the 8' lengths you will find at the lumberyard. For an "instant boat" the usual manner of joining the panels together to get one long panel is with a butt strap or butt plate. I've tried lots of different ways to make the joint in the 15 or so boats I've built over the years. All the methods worked. I have a feeling that the butt joints on the usual instant boat hull are not highly loaded and not too critical to overall boat strength. Since I've tried several ways and they all worked I've gotten to be pretty nebulous about the subject on my drawings. Lately I've been specifiying a butt plate as something like 'Butt plate from 3/4 x 3-1/2 lumber, or equal" which doesn't tell you much. Most builders get by pretty well with just that but recently one builder asked what in the world I meant, and rightly so. So let's start the discussion with one joint I've never tried in plywood.
TRADITIONAL PLYWOOD SCARF JOINT...
Figure 1 shows the traditional plywood scarf joint. I''ve never done this in plywood although I've made a lot of scarf joints in plain lumber. The two overlapping faces are tapered and glued together such that both joined faces remain smooth. If you are building a traditional lapstrake boat from plywood you have to make the joints this way.
What's good about it? The faces are smooth both sides. Essentially you have a single piece of wood to work with after making the joint. It's quite strong, as strong as the base wood provided the taper is long enough. I've seen the taper range from 6:1 to 12:1. The shorter tapers are easier to make and probably just as good given modern glues.
What's bad about it? The tapers can be hard to make properly although thickened epoxy has made experts of most of us. Some experts have special saw rigs to cut the taper. Most use power hand planes or belt sanders, I think. When gluing the joint you must press it up against a firm surface while the glue cures, making sure nothing glues to that surface, and making sure the two pieces are secured lengthwise so the tapers don't push them apart as you apply clamping pressure.
There is one more warning for instant boat builders. Almost all instant boat designs have panels layouts which assume you will not be using a scarf joint. If you join two 8' panels with a scarf joint you will NOT end up with a 16' panel. It will be shorter by the overlap amount. That might be just enought to negate the ply panel layout.
THE PAYSON TEAL BUTT STRAP...
I think this type of joint was described in Payson's great book INSTANT BOATS. I used it on my Teal which was my first homemade boat. The side panels were 1/4" thick on my boat, the bottom 3/8". The butt straps were 3/8" plywood, 6" wide. So the effect of the joint was similar to a 12;1 scarf on the 1/4" ply sides and about 8:1 scarf on the bottom. The nails were supposed to be copper, but I think Harold might have also suggested copper rivets or short bolts for fasteners.
What's good about it? It's pretty simple to visualize and make. If the fastening is good you can make the joint and go right on building without waiting for the glue to set. You might do that with the sides, for example. Another neat thing about this plain butt strap joint is that, with a typical flat iron skiff type of assembly, the bottom panels need not be joined before assembly onto the hull. In that case you will have the hull inverted on sawhorses ready for the bottom. Then you put the first bottom piece on attaching it to the sides. Then you install the first butt strap at the end of that piece. Then you install the next bottom panel to that butt strap and the sides. And so forth until the entire bottom is planked, like laying bricks.
I might mention now that I think butt straps and plates should be well rounded at the ends to avoid trapping dirt and moisture. In boats that have taped seams I advise stopping the butt strap short of the edge of the panel so you will have room to run the tapes undisturbed. This is especially true of butt straps on the bottom. You must have a clear limber channel around the perimenter of the bottom. In that case I stop the strap about 1/2" short of the side, fill the little gap with epoxy to keep the water out, and tape over the bottom of the joint with glass tape and epoxy. Usually I don't put glass tape over the outside of the side panel joints. But butt joints in any deck should be well sealed with glass and epoxy. Here is an end view of the treatment:
What's bad about the plywood strap? I think in Maine you aren't a man until you've made a boat with clenched copper nails or rivets. Not so where I live, can't buy them any place I know of. I got by with bronze boat nails but they really aren't flexible enough for the job. They didn't look too cool. And the edges of the plywood butt straps don't look too cool either, wanting to have gaps and splinters showing. It takes a while to finish them. And, of course, you have a lump at each joint and folks will ask, "What's that?"
By the way, when I built my Toto I used the simple plywood strap method with no fasteners. Just carefully lay the ply panels over the straps which were well buttered with glue, weighed it all down with concrete blocks to provide pressure, and stayed away for a few days until I was sure the glue was totally set.
THE BIRDWATCHER BUTT STRAP...
When I built my Birdwatcer in 1988 I think I piled on more layers of plywood straps such that I wouldn't have to bend over the nails. And by that time I was more expert at finishing the edges of plywood. It worked but it was very obvious that I could have done the same thing with regular lumber and saved a bit of work.
THE LUMBER BUTT PLATE...
This is what I like to advise now. Not much to it. Very quick and easy to make. Some say it looks too clunky for their tastes.
If there has been any structural problem with the above butt plate it is at the ends of a plate that joins bottom panels, ending short of the sides to allow a limber path. If the ends of the plate are not solidly glued and fastened to the bottom panels the butt plate will eventually loosen at the ends. I think that is due to the rapid change in flexibility in the system where the plate suddenly ends. A better solution might be to taper the end of the bottom butt plates starting maybe 3" in from the end of the plate and tapering down to maybe 3/8" thick at the ends. That will allow a gradual change in the flexibility and prevent a stress riser at the end of the butt plate. By the way, for any bulky butt joint care must be taken in design to see that the joints don't fail in places where the butt plate will be in the way.
LIGHT FIBERGLASS BUTT JOINTS..
Both Harold Payson and Dave Carnell presented this one to U.S. readers in the '80's but I'll bet the English inventors of taped seam boats did it earlier. Simple as can be in theory. Just a layer of fiberglass on each side of the plywood.
Dave Carnell presents lots of details at his web site. He has done scientific load tests of these joints and says the joint will be as strong as the base wood if you use one layer of fiberglass cloth in epoxy on each side of 1/4" plywood, two layers on 3/8" plywood, three layers on 1/2" plywood, and four layers on 3/4" plywood.
I used the glass butt joint on my Roar rowboat but went back to wooden butt joints later. At first it would appear that the joint is easily made by laying the ply pieces on the floor, taping one side with fiberglass, waiting to cure, flipping the panel and repeating on the other side. But I found that plywood on its own often does not want to lay flat enough to get a smooth fit, so I had to place the joint over a board and screw the pieces down flat. Next the idea of flipping the panel with only one side taped doesn't work well because that one layer of glass has little strength by itself. But it can be done carefully. Better yet is what both Payson and Carnell advise: glass both sides at once. Lay the first side of fiberglass layers wet with epoxy on a protected flat surface, lay the plywood to be joined upon it, lay the second side of fiberglass over the top of the joint, cover with plastic sheet and weigh down with concrete blocks. The plastic sheeting not only protects everything from gooey epoxy, but it should provide a smooth final finish and if you are lucky no filling or sanding required afterward.
THE PAYSON HEAVY GLASS JOINT...
Harold Payson did a little more work on the glass butt joint. I'm doing this from memory and hope I'm getting it right. To hide the build up of glass on a thicker sheet of plywood he recessed the surfaces roughly with a sanding disk in a drill. Then he added a layer of light fiberglass matt to the wood before pasting in the glass. Fiberglass matt is generally thought to provide better adhesion to wood than glass cloth although by itself it has little strength. Harold is big on using polyester resin on his boats instead of epoxy so perhaps the matt is more important for the polyester users. But you can see the advantage of the system: the final joint can be more or less invisible as the multiple layers of glass are recessed.
Philsboat
PHILSBOAT, SAILBOAT, 15' X 5.5', 550 POUNDS EMPTY
Philsboat is essentially an IMB with the nose extended to a pointy bow. The width and multichine configuration are the same as IMB's. The cabin is 3" deeper because Phil is at least 3" taller than most of us. In a boat with a Birdwatcher cabin like this one added depth to the cabin makes it safer in that the righting forces in a knockdown are greater. That would be true of any boat if the center of gravity did not move with the cabin roof but with the normal cruiser adding depth to the cabin also means raising the crew deck up so the folks can see over the raised cabin. And that means the CG is elevated too, and then all bets are off concerning self righting. But with a boat like Philsboat eveyone rides down low inside looking out through the windows.
Here is a photo of Bob Williams' IMB:
In addition to the pointy bow and added headroom I added what I hope is a serious motor mount. Probably 3hp will drive it as fast as it will ever go and that at part throttle. But the motor well gets to looking pretty large even for such a small motor. For one thing it must be deep to put a short shaft motor on a deep stern like this so I ran it straight down to the boat's bottom. Working on the motor down it its well will be about impossible and you might need to keep an eye on your knuckles when you pull the starting rope. And the well must be surprisingly wide to allow the motor to swivel in steering although the usual case here will be to keep the motor locked straight ahead and steer with the tiller. The wide well pushed the rudder off center and you need a crooked tiller or rudder linkage to make it all work. I opted for a simple but crooked tiller.
I also added low seats like those I saw added to the two IMB's that came to the Lake Conroe Messabout. Pretty much the same as what I have in Scram Pram where the seats do double duty as water ballast tanks. Philsboat seats could easily be converted into water ballast tanks also but the IMB capsize tests imply the ballast isn't needed.
The sail rig uses a balanced lug, 113 square feet and the same as that of a Bolger Windsprint.
Philsboat uses taped seam construction. Five sheets of 1/4" plywood, five sheets of 3/8" and three sheets of 1/2" plywood.
Actually the size and material list for Philsboat are about the same as that of Scram Pram. So which boat would be better? Take Philsboat if you are a pointy bow guy. It should be better in really rough water. On the other hand Scram is wider and roomier. It has a flat step through bow that will splash and spit in rough water but makes beaching a very nice experience.
Update, 2007. Chris Feller completed his Philsboat, probably the first prototype completed, and brought it to the 2007 Rend Lake Messabout. Very well made and to plans except he used the 91 sq ft lugsail he had on hand for his AF3, with some mast rake changes he calculated with his "sail area math". Sailed correctly rigtht off the drawing board, so to speak. We had a chance to use it for a few really nice days. In a good sailing breeze, say 10 to 15 knots with occasional whitecaps, our gps bobbed between 5.5 and 6mph for two hours of reaching as we crossed back and forth on the big lake. When I used the Philsboat I thought it was probably just as easy to enter from a beach as the blunt bowed Scram. The front deck is about 2' high so you can sit on it and swing you legs around onto the deck and then into the cabin.
Chris is a big boy but there was plenty of room inside for the two of us and more. Rumor has it that at the campsite the night before Chris slept in the Philsboat on the trailer with an airconditioner in the front hatch plugged into the campsite power. So the boat is plenty big in the way most people would use it.
The stern layout has the motor in a small well to one side and the rudder offset to the other side to give the motor room to swing. There is no linkage to the tiller, the tiller is simply "unstraight" so that is falls on centerline at the skipper's hand. Seems to work well and is quite simple. Chris uses a 2hp Honda which has a fairly large cowling for its size and must be rotated 180 degrees to grab reverse. He said the motor well size is a bit too small for that. Karl James had the same problem with his Jewelbox a long time ago and simply cut away the side of the hull in top of the motor well region - after all it is just there for looks. Chris said he tried the boat under power and found it went 6 mph max, just like under sail. No surprize to me. My Birdwatcher also maxes out at 6mph under 3hp and under 5.5 hp. This sort of hull will only go so fast. Add more power and you just dig a deeper hole and make a bigger wake - you won't go faster. But sometimes more power is nice on a windy day.
(As an update, Chris has brought his Philsboat to several more Rend Lake meets. In 2008 the meet was very windy and Philsboat got a full windows wet knockdown with Chris and Tom Hamernik on board. She self righted with no issues and they kept right on sailing, but Chris confessed he has 100 pounds of lead shot under the seats. Also he is using a 3hp vintage Johnson which he says is quieter and smoother than the Honda.)
You might recall from the Prototypes section recently that there was another Philsboat being built in California. That one last I heard was about to be launched. Has more changes from blueprint than Chris's boat but still is pretty true to form. Seems to be known as Bumble and made by Rex Meach.
And in New Zealand Rob Kellock has been sailing his with a junk rig. He has been knocked down a couple of times and self righted as planned:
Plans for Philsboat are $45.
Prototype News
Some of you may know that in addition to the one buck catalog which now contains 20 "done" boats, I offer another catalog of 20 unbuilt prototypes. The buck catalog has on its last page a list and brief description of the boats currently in the Catalog of Prototypes. That catalog also contains some articles that I wrote for Messing About In Boats and Boatbuilder magazines. The Catalog of Prototypes costs $3. The both together amount to 50 pages for $4, an offer you may have seen in Woodenboat ads. Payment must be in US funds. The banks here won't accept anything else. (I've got a little stash of foreign currency that I can admire but not spend.) I'm way too small for credit cards.
We have a Picara finished by Ken Giles, past Mayfly16 master, and into its trials. The hull was built by Vincent Lavender in Massachusetts. There have been other Picaras finished in the past but I never got a sailing report for them...
And the Vole in New York is Garth Battista's of www.breakawaybooks.com, printer of my book and Max's old outboard book and many other fine sports books. Beautiful job! Garth is using a small lug rig for sail, not the sharpie sprit sail shown on the plans, so I will continue to carry the design as a prototype boat. But he has used it extensively on his Bahamas trip towed behind his Cormorant. Sort of like having a compact car towed behind an RV.
And a Deansbox seen in Texas:
Another prototype Twister is well along:
A brave soul has started a Robbsboat. He has a builder's blog at http://tomsrobbsboat.blogspot.com. (OOPS! He found a mistake in the side bevels of bulkhead5, says 20 degrees but should be 10 degrees.) This boat has been sailed and is being tested. He has found the sail area a bit much for his area and is putting in serious reef points.
Herb McLeod in Canada has finished the first OliveOyl and is now testing..
AN INDEX OF PAST ISSUES
THE WAY BACK ISSUES RETURN!
MANY THANKS TO CANADIAN READER GAETAN JETTE WHO NOT ONLY SAVED THEM FROM THE 1997 BEGINNING BUT ALSO PUT TOGETHER AN EXCELLENT INDEX PAGE TO SORT THEM OUT....
THE WAY BACK ISSUES
1oct16, D'Arcy Ballast, Larsboat
15oct16, D'Arcy Ballast 2, Jonsboat
1nov16, D'Arcy Ballast 3, Piccup Pram
1dec16, Sail Area Math, Ladybug
15dec16, D'Arcy Thoughts, Sportdory
1jan17, AF3 Capsize, Normsboat
15jan17, The Weather, Robote
1feb17, Aspect Ratio, Jewelbox Jr
15feb17, Aspect Ratio 2, IMB
1mar17, Normsboat Capsize, AF4Breve
15mar17, Underwater Board Shape, Harmonica
1apr17, Capsize Lesson, RiverRunner
15apr17, Measuring Leeway, Mayfly16
1may17, Scarfing Lumber, Blobster
15may17, Rigging Lugsails, QT Skiff
1jun17, Rowing1, Mayfly14
15jun17, Rend Lake 2017, Mixer
1jul17, Rowing2, Viola14
15jul17, Rowing3, Vamp
Table of Contents
