Cathead

American western river steamboats represent a unique form of shipbuilding. Designed and built on the American frontier during the core of the 19th century, such boats rapidly evolved to fit the specific needs of the great inland river systems that drained inland North America. In this build I will replicate a typical specimen of this design, the steamboat Bertrand, trying to accurately duplicate the features of these fascinating vessels. I hope you’ll follow along, both to enjoy the construction, and to learn about this obscure but fascinating (to me, at least) part of maritime transportation history. These boats are almost, but not entirely, unlike an ocean-going vessel of the same period, in large part due to the demands of their specific riverine habitat. Below, my updated workbench with Bertrand profile on the wall for inspiration.
 

 
The “western” in western river steamboat refers to the landscape between the Appalachian and Rocky Mountains. Over the course of the 19th century, this area went from the mostly unknown wilderness of Lewis & Clark’s 1804 expedition up the Missouri River, to a land mostly settled and integrated into the United States by the dawn of the 20th century. Most of this landscape centers on the Mississippi River basin, including its major tributaries such as the Ohio and Missouri Rivers. This system drains over 1 million square miles (almost 3 million square km), covering parts of 31 American states and 2 Canadian provinces. Almost all the rivers in the system were navigable in the 19th century for most of their lengths, creating a vast trade and transportation network across the continent’s interior long before railroads appeared on the scene, when roads were all but non-existent (map below from National Park Service).
 

 
The Bertand, built in 1864 and sunk in 1865, was a wholly typical and unremarkable western river steamer, except for its rediscovery beneath a US Wildlife Refuge along the Iowa/Nebraska border in 1968. The boat and its cargo were remarkably well-preserved, due to quick burial beneath river sediment by the quickly changing channel of the Missouri River, and the anoxic environment thus produced. The Bertrand’s mint-condition cargo is now on display at a fascinating museum at the DeSoto National Wildlife Refuge, which also hosts a detailed large-scale model of the craft (shown below). The archeological excavation of the craft resulted in a plethora of information about period steamboat construction. In pairing with the later, but similar, discovery of the sunken steamboat Arabia along the Kansas/Missouri border and subsequent founding of a similar museum in Kansas City, the two wrecks represent a spectacular repository of historical and maritime knowledge and preservation. Below, the gorgeous large-scale model of Bertrand at DeSoto (FWS photo).
 

 
I live and farm near the Missouri River, and have long been fascinated by the history of its steamboats. My first-ever attempt at wooden ship modeling was a scratchbuilt version of the Far West, perhaps the most famous of its class, a sternwheeler which ascended the Missouri and Yellowstone Rivers to extraordinary distances, and carried General Custer’s troops to and from the infamous Battle of Little Big Horn. The Bertrand is a similar craft to the Far West, which was built to ascent the shallow, treacherous river to Montana, while the Arabia was a sidewheeler more typical  of the lower Missouri River below Omaha, Nebraska (and the Ohio and Mississippi). I had initially intended to build the Arabia next, but due to a lack of available plans, and my inability to make it to Kansas City to do research at her eponymous museum, I changed my focus to the Bertrand. Below, my model of the Far West for context:
 

 
I’ve had plans for the Bertrand for several years, having purchased them at the same time as my Far West plans, and consulted them on that project. Now, the goal is a similar boat but at much greater detail: I would like to build the Bertrand frame-by-frame, just as initially constructed in the riverside yards at Wheeling, West Virginia. I have a shelf of texts on western steamboat history and construction, and several more detailed references on the excavation of the Bertrand on order through inter-library loan. I intend to leave one side of the hull unplanked, and possibly the same side of the superstructure, to show full detail throughout. Below, longitudinal internal section of the Bertrand from the plans I'll be using.
 

 
I hope you’ll join me on this (likely) wordy trek through a relatively unknown period of American maritime history and design. Few other steamboats grace this site, so I'd like to fill the gap a little with this project. I’ll try to interweave build details with explanations and demonstrations of why the boat was designed and built the way it was, to give context to this project and help share my love of these steamboats and their (my) home. This project is a significant undertaking for me, a serious step up from my previous Bounty launch kit and various smaller and less-detailed scratchbuilding efforts. I hope to be open to suggestion and advice, and I hope readers will be patient with the slow progress I'll likely make as I juggle this project with the summertime demands on my time, as well as the budget necessary to do this with my uncertain income as a self-employed farmer and writer. Welcome aboard, and unlike most boats of this type, we'll hope this one doesn't sink or blow up on the journey! 
 
UPDATE: Build completed and index available.
I finished this project in January 2016, and compiled an index of the general steps involved, with links to each one. You can review the build index here, in a post at the end of this log.

Kurt,
 
Multiple sources discuss possible paint schemes for Bertrand, though little is known for sure. Most similar boats were painted white, with some trim in other colors. The main deck was often either red or natural wood. The model on display at DeSoto NWR, of which I included a photo in the opening post of this build, seems to match the color scheme most commonly attributed to Bertrand based on my reading. Here's another view of it:
 

Kurt,
 
Multiple sources discuss possible paint schemes for Bertrand, though little is known for sure. Most similar boats were painted white, with some trim in other colors. The main deck was often either red or natural wood. The model on display at DeSoto NWR, of which I included a photo in the opening post of this build, seems to match the color scheme most commonly attributed to Bertrand based on my reading. Here's another view of it:
 

Kurt,
 
Multiple sources discuss possible paint schemes for Bertrand, though little is known for sure. Most similar boats were painted white, with some trim in other colors. The main deck was often either red or natural wood. The model on display at DeSoto NWR, of which I included a photo in the opening post of this build, seems to match the color scheme most commonly attributed to Bertrand based on my reading. Here's another view of it:
 

Kurt,
 
Multiple sources discuss possible paint schemes for Bertrand, though little is known for sure. Most similar boats were painted white, with some trim in other colors. The main deck was often either red or natural wood. The model on display at DeSoto NWR, of which I included a photo in the opening post of this build, seems to match the color scheme most commonly attributed to Bertrand based on my reading. Here's another view of it:
 

Kurt,
 
Multiple sources discuss possible paint schemes for Bertrand, though little is known for sure. Most similar boats were painted white, with some trim in other colors. The main deck was often either red or natural wood. The model on display at DeSoto NWR, of which I included a photo in the opening post of this build, seems to match the color scheme most commonly attributed to Bertrand based on my reading. Here's another view of it:
 

Kurt,
 
Multiple sources discuss possible paint schemes for Bertrand, though little is known for sure. Most similar boats were painted white, with some trim in other colors. The main deck was often either red or natural wood. The model on display at DeSoto NWR, of which I included a photo in the opening post of this build, seems to match the color scheme most commonly attributed to Bertrand based on my reading. Here's another view of it:
 

Oh, don't worry, I'm just speculating. It doesn't affect anything yet, I intend to fully frame and at least half-plank the hull before deciding what to do next. It'll be a while... Thanks for all the likes!

Kurt,
 
Multiple sources discuss possible paint schemes for Bertrand, though little is known for sure. Most similar boats were painted white, with some trim in other colors. The main deck was often either red or natural wood. The model on display at DeSoto NWR, of which I included a photo in the opening post of this build, seems to match the color scheme most commonly attributed to Bertrand based on my reading. Here's another view of it:
 

I can remember taking something like this to a club meeting and people saying you build well with matchsticks.  Cathead you are doing well too.
 
Bob

The hull is developing nicely. I had a close shave with my floors, having estimated the required pieces too close for comfort, and not being sure until the very end that I'd have enough. Phew!
 
All the vertical frames are assembled and in place, attached with stringers. As the futtocks at bow and stern are angled, I plan to install them one at a time, to fit. Thus I'm now working to bend and attach an interior stringer at the deck line, to which I can measure & attach each futtock. For example, here's the bow:
 

 
I soaked these two long pieces in a cookie tray of boiling water, then bent them around a jury-rigged frame to the correct curve. Once they're dry, I'll glue them in place and have a solid reference point for the rest of the futtocks. Note the gentle sheer leading up to the stem. Here's the stern:
 

 
It's a bit simpler here. The stern is squared off, with a simple curve leading up to the deck. I cut out appropriate molds on my bandsaw, then glued them into an appropriate arrangement for bending the internal stringers. Like the bow, I soaked these in boiling water before bending them into place. As shown, they represent the actual shape of the stern (upside down) quite well. Once these are in place, I'll connect them to the existing stringers in the rest of the hull. Note that the last 8 futtocks are extra-long; this is because the stem also has a rising sheer, beginning there, so I cut those pieces longer to allow for trimming to the exact length once a final stringer is installed.
 
Other notes: while I could have installed all the internal stringers as one long piece, my internal perfectionist got the better of me and I instead cut them into regular, scarf-jointed planks (the actual builders wouldn't have had planks over 100' long!). These joints don't show up in the overexposed photo 1, but they're there. Also, the keelson will need to be built up with several layers of planking, but I won't do that until later.
 
Coming up next, I'll build the stern and connect the deck-level stringer all the way around, and start the tedious job of custom-cutting and -fitting the ~100 futtocks needed to complete the hull framing.
 
This has been great fun so far, and while I'm not particularly looking forward to all the fussy cant frames coming up, I love the geometry of open full framing. A voice in my mind is suggesting that I change course dramatically and build this simply as an open-hull model, with no superstructure at all, perhaps with the deck half-planked at most. What think you all?
 

The hull is developing nicely. I had a close shave with my floors, having estimated the required pieces too close for comfort, and not being sure until the very end that I'd have enough. Phew!
 
All the vertical frames are assembled and in place, attached with stringers. As the futtocks at bow and stern are angled, I plan to install them one at a time, to fit. Thus I'm now working to bend and attach an interior stringer at the deck line, to which I can measure & attach each futtock. For example, here's the bow:
 

 
I soaked these two long pieces in a cookie tray of boiling water, then bent them around a jury-rigged frame to the correct curve. Once they're dry, I'll glue them in place and have a solid reference point for the rest of the futtocks. Note the gentle sheer leading up to the stem. Here's the stern:
 

 
It's a bit simpler here. The stern is squared off, with a simple curve leading up to the deck. I cut out appropriate molds on my bandsaw, then glued them into an appropriate arrangement for bending the internal stringers. Like the bow, I soaked these in boiling water before bending them into place. As shown, they represent the actual shape of the stern (upside down) quite well. Once these are in place, I'll connect them to the existing stringers in the rest of the hull. Note that the last 8 futtocks are extra-long; this is because the stem also has a rising sheer, beginning there, so I cut those pieces longer to allow for trimming to the exact length once a final stringer is installed.
 
Other notes: while I could have installed all the internal stringers as one long piece, my internal perfectionist got the better of me and I instead cut them into regular, scarf-jointed planks (the actual builders wouldn't have had planks over 100' long!). These joints don't show up in the overexposed photo 1, but they're there. Also, the keelson will need to be built up with several layers of planking, but I won't do that until later.
 
Coming up next, I'll build the stern and connect the deck-level stringer all the way around, and start the tedious job of custom-cutting and -fitting the ~100 futtocks needed to complete the hull framing.
 
This has been great fun so far, and while I'm not particularly looking forward to all the fussy cant frames coming up, I love the geometry of open full framing. A voice in my mind is suggesting that I change course dramatically and build this simply as an open-hull model, with no superstructure at all, perhaps with the deck half-planked at most. What think you all?
 

The hull is developing nicely. I had a close shave with my floors, having estimated the required pieces too close for comfort, and not being sure until the very end that I'd have enough. Phew!
 
All the vertical frames are assembled and in place, attached with stringers. As the futtocks at bow and stern are angled, I plan to install them one at a time, to fit. Thus I'm now working to bend and attach an interior stringer at the deck line, to which I can measure & attach each futtock. For example, here's the bow:
 

 
I soaked these two long pieces in a cookie tray of boiling water, then bent them around a jury-rigged frame to the correct curve. Once they're dry, I'll glue them in place and have a solid reference point for the rest of the futtocks. Note the gentle sheer leading up to the stem. Here's the stern:
 

 
It's a bit simpler here. The stern is squared off, with a simple curve leading up to the deck. I cut out appropriate molds on my bandsaw, then glued them into an appropriate arrangement for bending the internal stringers. Like the bow, I soaked these in boiling water before bending them into place. As shown, they represent the actual shape of the stern (upside down) quite well. Once these are in place, I'll connect them to the existing stringers in the rest of the hull. Note that the last 8 futtocks are extra-long; this is because the stem also has a rising sheer, beginning there, so I cut those pieces longer to allow for trimming to the exact length once a final stringer is installed.
 
Other notes: while I could have installed all the internal stringers as one long piece, my internal perfectionist got the better of me and I instead cut them into regular, scarf-jointed planks (the actual builders wouldn't have had planks over 100' long!). These joints don't show up in the overexposed photo 1, but they're there. Also, the keelson will need to be built up with several layers of planking, but I won't do that until later.
 
Coming up next, I'll build the stern and connect the deck-level stringer all the way around, and start the tedious job of custom-cutting and -fitting the ~100 futtocks needed to complete the hull framing.
 
This has been great fun so far, and while I'm not particularly looking forward to all the fussy cant frames coming up, I love the geometry of open full framing. A voice in my mind is suggesting that I change course dramatically and build this simply as an open-hull model, with no superstructure at all, perhaps with the deck half-planked at most. What think you all?
 

The hull is developing nicely. I had a close shave with my floors, having estimated the required pieces too close for comfort, and not being sure until the very end that I'd have enough. Phew!
 
All the vertical frames are assembled and in place, attached with stringers. As the futtocks at bow and stern are angled, I plan to install them one at a time, to fit. Thus I'm now working to bend and attach an interior stringer at the deck line, to which I can measure & attach each futtock. For example, here's the bow:
 

 
I soaked these two long pieces in a cookie tray of boiling water, then bent them around a jury-rigged frame to the correct curve. Once they're dry, I'll glue them in place and have a solid reference point for the rest of the futtocks. Note the gentle sheer leading up to the stem. Here's the stern:
 

 
It's a bit simpler here. The stern is squared off, with a simple curve leading up to the deck. I cut out appropriate molds on my bandsaw, then glued them into an appropriate arrangement for bending the internal stringers. Like the bow, I soaked these in boiling water before bending them into place. As shown, they represent the actual shape of the stern (upside down) quite well. Once these are in place, I'll connect them to the existing stringers in the rest of the hull. Note that the last 8 futtocks are extra-long; this is because the stem also has a rising sheer, beginning there, so I cut those pieces longer to allow for trimming to the exact length once a final stringer is installed.
 
Other notes: while I could have installed all the internal stringers as one long piece, my internal perfectionist got the better of me and I instead cut them into regular, scarf-jointed planks (the actual builders wouldn't have had planks over 100' long!). These joints don't show up in the overexposed photo 1, but they're there. Also, the keelson will need to be built up with several layers of planking, but I won't do that until later.
 
Coming up next, I'll build the stern and connect the deck-level stringer all the way around, and start the tedious job of custom-cutting and -fitting the ~100 futtocks needed to complete the hull framing.
 
This has been great fun so far, and while I'm not particularly looking forward to all the fussy cant frames coming up, I love the geometry of open full framing. A voice in my mind is suggesting that I change course dramatically and build this simply as an open-hull model, with no superstructure at all, perhaps with the deck half-planked at most. What think you all?
 

The hull is developing nicely. I had a close shave with my floors, having estimated the required pieces too close for comfort, and not being sure until the very end that I'd have enough. Phew!
 
All the vertical frames are assembled and in place, attached with stringers. As the futtocks at bow and stern are angled, I plan to install them one at a time, to fit. Thus I'm now working to bend and attach an interior stringer at the deck line, to which I can measure & attach each futtock. For example, here's the bow:
 

 
I soaked these two long pieces in a cookie tray of boiling water, then bent them around a jury-rigged frame to the correct curve. Once they're dry, I'll glue them in place and have a solid reference point for the rest of the futtocks. Note the gentle sheer leading up to the stem. Here's the stern:
 

 
It's a bit simpler here. The stern is squared off, with a simple curve leading up to the deck. I cut out appropriate molds on my bandsaw, then glued them into an appropriate arrangement for bending the internal stringers. Like the bow, I soaked these in boiling water before bending them into place. As shown, they represent the actual shape of the stern (upside down) quite well. Once these are in place, I'll connect them to the existing stringers in the rest of the hull. Note that the last 8 futtocks are extra-long; this is because the stem also has a rising sheer, beginning there, so I cut those pieces longer to allow for trimming to the exact length once a final stringer is installed.
 
Other notes: while I could have installed all the internal stringers as one long piece, my internal perfectionist got the better of me and I instead cut them into regular, scarf-jointed planks (the actual builders wouldn't have had planks over 100' long!). These joints don't show up in the overexposed photo 1, but they're there. Also, the keelson will need to be built up with several layers of planking, but I won't do that until later.
 
Coming up next, I'll build the stern and connect the deck-level stringer all the way around, and start the tedious job of custom-cutting and -fitting the ~100 futtocks needed to complete the hull framing.
 
This has been great fun so far, and while I'm not particularly looking forward to all the fussy cant frames coming up, I love the geometry of open full framing. A voice in my mind is suggesting that I change course dramatically and build this simply as an open-hull model, with no superstructure at all, perhaps with the deck half-planked at most. What think you all?
 

The hull is developing nicely. I had a close shave with my floors, having estimated the required pieces too close for comfort, and not being sure until the very end that I'd have enough. Phew!
 
All the vertical frames are assembled and in place, attached with stringers. As the futtocks at bow and stern are angled, I plan to install them one at a time, to fit. Thus I'm now working to bend and attach an interior stringer at the deck line, to which I can measure & attach each futtock. For example, here's the bow:
 

 
I soaked these two long pieces in a cookie tray of boiling water, then bent them around a jury-rigged frame to the correct curve. Once they're dry, I'll glue them in place and have a solid reference point for the rest of the futtocks. Note the gentle sheer leading up to the stem. Here's the stern:
 

 
It's a bit simpler here. The stern is squared off, with a simple curve leading up to the deck. I cut out appropriate molds on my bandsaw, then glued them into an appropriate arrangement for bending the internal stringers. Like the bow, I soaked these in boiling water before bending them into place. As shown, they represent the actual shape of the stern (upside down) quite well. Once these are in place, I'll connect them to the existing stringers in the rest of the hull. Note that the last 8 futtocks are extra-long; this is because the stem also has a rising sheer, beginning there, so I cut those pieces longer to allow for trimming to the exact length once a final stringer is installed.
 
Other notes: while I could have installed all the internal stringers as one long piece, my internal perfectionist got the better of me and I instead cut them into regular, scarf-jointed planks (the actual builders wouldn't have had planks over 100' long!). These joints don't show up in the overexposed photo 1, but they're there. Also, the keelson will need to be built up with several layers of planking, but I won't do that until later.
 
Coming up next, I'll build the stern and connect the deck-level stringer all the way around, and start the tedious job of custom-cutting and -fitting the ~100 futtocks needed to complete the hull framing.
 
This has been great fun so far, and while I'm not particularly looking forward to all the fussy cant frames coming up, I love the geometry of open full framing. A voice in my mind is suggesting that I change course dramatically and build this simply as an open-hull model, with no superstructure at all, perhaps with the deck half-planked at most. What think you all?
 

The Bertrand, version 2.0, is underway!
 

 
Above, you see a set of mid-hull frames assembled and laid out at the prototype spacing of about 15 scale inches. Astute observers may notice something different from earlier in this log: these frames are built at a 90 degree angle (floor to futtock), not canted outward. The more I compared my purchased plans to the original archeological drawings now in my possession, the more blatant errors I found. I've now pretty much abandoned those first plans and spent some time scanning and resizing the new drawings to 1:87 scale and hitting the reset button on pretty much everything involved with this project. Hence the delay in updating this log, along with a busy few weeks in real life. 
 
According to the actual archeological notes (from here on referred to as the Petsche plans after the leader of the excavation team), Bertrand very definitely had squared-off mid-hull frames, with angles only occurring at stem and stern. In other words, this plan view and the frames I built from it were totally wrong:
 

 
So I designed a new set of frame molds and have been busy mass-producing frames:
 

 
I do these eight at a time, pre-cutting the floors and futtocks on my trusty cutter (upper left), then assembling them around the wooden molds seen at right. These are pinned to a piece of foam board, holding everything in place. I pin a floor in place, dip each futtock in wood glue, then fit it in place along the side of the form, using another pin on each side. Then I use the cutter to create the tiny angle braces, smear some more glue across the joint, and use tweezers to install each angle brace on top. Below is a detail of several of these assemblies:
 

 
When these are dry, I use the cutter to lop a small 45 degree angle off each bilge corner, where a bilge plank will go. These areas were not rounded as on a sea-going vessel, but angular, which made construction much easier for the craftsmen assembling these boats in the American wilderness of the upper Ohio River. Note that the molds have a 45 degree angle cut out at the turn of the bilge. This is so I can glue the bilge together without anything sticking to the mold. The remainder of the frame is sufficient to hold the pieces at a proper 90 degree angle. Anything that sticks to the foam board is popped off with a flat knife blade and sanded smooth.
 
Here's an overhead view of my hull setup:
 

 
A copy of the inner hull plan is attached to the build board with double-sided tape. Several layers of wooden strips line both sides of the hull to provide consistent support for the frames (also attached with tape). The plans then have four thin strips of double-sided tape run on top, to hold the frames in place during assembly. I use wooden spacers to support each frame, keeping it at the proper distance from its neighbors and properly vertical. In these photos, I've removed some spacers temporarily so you can see more detail. I've used tape for everything to allow adjustment is necessary, and it works great. This jig was very much inspired by the Cairo build suggested earlier in this log (thanks, Ken!)
 
As each batch of 8 frames is ready, I add them to the hull jig. It takes 15-20 minutes to build 8 frames, then a few hours for the glue to dry. I basically do a batch any evening I have a short stretch of time to spare, and slowly but surely work my way toward the daunting total quantity needed. This means I don't get overwhelmed trying to do them all at once, or keep count. 
 
Once I reach the beginning of stem and stern curves, I will have to build the frames custom-in-place, but as the standard square frames make up much of the boat's total length, this will be manageable.When all the standard frames are done, I'll start installing the keelson and other stringers to hold the structure firmly together, then proceed on the more complex ends.
 
So that's where the Bertrand stands this weekend. I will do another update when these square frames are completed and I've started in on the interesting challenge of stem & stern. Hopefully the wait won't be as long this time!
 

Jim,
 
Indeed I feel fortunate, though as you'll discover later on, the fortune only lasts so far. None of Bertrand's superstructure was present by the time of excavation, so while the hull was thoroughly documented, everything above the main deck is based on conjecture and extrapolation. I'll delve into that when we get there.
 
My original plan was just as you say, to leave one half of the hull unplanked. However, when I realized just how close the frames would be (unlike my first set of plans), I became worried that you wouldn't be able to see in enough, and so started considering other options like holes in the hull or a removable main deck. I have been considering and experimenting with different approaches on the side, and will discuss that more, later as well.

Jim,
 
Indeed I feel fortunate, though as you'll discover later on, the fortune only lasts so far. None of Bertrand's superstructure was present by the time of excavation, so while the hull was thoroughly documented, everything above the main deck is based on conjecture and extrapolation. I'll delve into that when we get there.
 
My original plan was just as you say, to leave one half of the hull unplanked. However, when I realized just how close the frames would be (unlike my first set of plans), I became worried that you wouldn't be able to see in enough, and so started considering other options like holes in the hull or a removable main deck. I have been considering and experimenting with different approaches on the side, and will discuss that more, later as well.

Absolutely brilliant that you were able to find such a detailed set of plans for your proposed build - if only that sort of information was always available.
 
As for the interior view - have you thought of simply leaving one half of the model entirely in frame?
 
John

Great catch on the plan profile. And a nice start on your build.

The Bertrand, version 2.0, is underway!
 

 
Above, you see a set of mid-hull frames assembled and laid out at the prototype spacing of about 15 scale inches. Astute observers may notice something different from earlier in this log: these frames are built at a 90 degree angle (floor to futtock), not canted outward. The more I compared my purchased plans to the original archeological drawings now in my possession, the more blatant errors I found. I've now pretty much abandoned those first plans and spent some time scanning and resizing the new drawings to 1:87 scale and hitting the reset button on pretty much everything involved with this project. Hence the delay in updating this log, along with a busy few weeks in real life. 
 
According to the actual archeological notes (from here on referred to as the Petsche plans after the leader of the excavation team), Bertrand very definitely had squared-off mid-hull frames, with angles only occurring at stem and stern. In other words, this plan view and the frames I built from it were totally wrong:
 

 
So I designed a new set of frame molds and have been busy mass-producing frames:
 

 
I do these eight at a time, pre-cutting the floors and futtocks on my trusty cutter (upper left), then assembling them around the wooden molds seen at right. These are pinned to a piece of foam board, holding everything in place. I pin a floor in place, dip each futtock in wood glue, then fit it in place along the side of the form, using another pin on each side. Then I use the cutter to create the tiny angle braces, smear some more glue across the joint, and use tweezers to install each angle brace on top. Below is a detail of several of these assemblies:
 

 
When these are dry, I use the cutter to lop a small 45 degree angle off each bilge corner, where a bilge plank will go. These areas were not rounded as on a sea-going vessel, but angular, which made construction much easier for the craftsmen assembling these boats in the American wilderness of the upper Ohio River. Note that the molds have a 45 degree angle cut out at the turn of the bilge. This is so I can glue the bilge together without anything sticking to the mold. The remainder of the frame is sufficient to hold the pieces at a proper 90 degree angle. Anything that sticks to the foam board is popped off with a flat knife blade and sanded smooth.
 
Here's an overhead view of my hull setup:
 

 
A copy of the inner hull plan is attached to the build board with double-sided tape. Several layers of wooden strips line both sides of the hull to provide consistent support for the frames (also attached with tape). The plans then have four thin strips of double-sided tape run on top, to hold the frames in place during assembly. I use wooden spacers to support each frame, keeping it at the proper distance from its neighbors and properly vertical. In these photos, I've removed some spacers temporarily so you can see more detail. I've used tape for everything to allow adjustment is necessary, and it works great. This jig was very much inspired by the Cairo build suggested earlier in this log (thanks, Ken!)
 
As each batch of 8 frames is ready, I add them to the hull jig. It takes 15-20 minutes to build 8 frames, then a few hours for the glue to dry. I basically do a batch any evening I have a short stretch of time to spare, and slowly but surely work my way toward the daunting total quantity needed. This means I don't get overwhelmed trying to do them all at once, or keep count. 
 
Once I reach the beginning of stem and stern curves, I will have to build the frames custom-in-place, but as the standard square frames make up much of the boat's total length, this will be manageable.When all the standard frames are done, I'll start installing the keelson and other stringers to hold the structure firmly together, then proceed on the more complex ends.
 
So that's where the Bertrand stands this weekend. I will do another update when these square frames are completed and I've started in on the interesting challenge of stem & stern. Hopefully the wait won't be as long this time!
 

The Bertrand, version 2.0, is underway!
 

 
Above, you see a set of mid-hull frames assembled and laid out at the prototype spacing of about 15 scale inches. Astute observers may notice something different from earlier in this log: these frames are built at a 90 degree angle (floor to futtock), not canted outward. The more I compared my purchased plans to the original archeological drawings now in my possession, the more blatant errors I found. I've now pretty much abandoned those first plans and spent some time scanning and resizing the new drawings to 1:87 scale and hitting the reset button on pretty much everything involved with this project. Hence the delay in updating this log, along with a busy few weeks in real life. 
 
According to the actual archeological notes (from here on referred to as the Petsche plans after the leader of the excavation team), Bertrand very definitely had squared-off mid-hull frames, with angles only occurring at stem and stern. In other words, this plan view and the frames I built from it were totally wrong:
 

 
So I designed a new set of frame molds and have been busy mass-producing frames:
 

 
I do these eight at a time, pre-cutting the floors and futtocks on my trusty cutter (upper left), then assembling them around the wooden molds seen at right. These are pinned to a piece of foam board, holding everything in place. I pin a floor in place, dip each futtock in wood glue, then fit it in place along the side of the form, using another pin on each side. Then I use the cutter to create the tiny angle braces, smear some more glue across the joint, and use tweezers to install each angle brace on top. Below is a detail of several of these assemblies:
 

 
When these are dry, I use the cutter to lop a small 45 degree angle off each bilge corner, where a bilge plank will go. These areas were not rounded as on a sea-going vessel, but angular, which made construction much easier for the craftsmen assembling these boats in the American wilderness of the upper Ohio River. Note that the molds have a 45 degree angle cut out at the turn of the bilge. This is so I can glue the bilge together without anything sticking to the mold. The remainder of the frame is sufficient to hold the pieces at a proper 90 degree angle. Anything that sticks to the foam board is popped off with a flat knife blade and sanded smooth.
 
Here's an overhead view of my hull setup:
 

 
A copy of the inner hull plan is attached to the build board with double-sided tape. Several layers of wooden strips line both sides of the hull to provide consistent support for the frames (also attached with tape). The plans then have four thin strips of double-sided tape run on top, to hold the frames in place during assembly. I use wooden spacers to support each frame, keeping it at the proper distance from its neighbors and properly vertical. In these photos, I've removed some spacers temporarily so you can see more detail. I've used tape for everything to allow adjustment is necessary, and it works great. This jig was very much inspired by the Cairo build suggested earlier in this log (thanks, Ken!)
 
As each batch of 8 frames is ready, I add them to the hull jig. It takes 15-20 minutes to build 8 frames, then a few hours for the glue to dry. I basically do a batch any evening I have a short stretch of time to spare, and slowly but surely work my way toward the daunting total quantity needed. This means I don't get overwhelmed trying to do them all at once, or keep count. 
 
Once I reach the beginning of stem and stern curves, I will have to build the frames custom-in-place, but as the standard square frames make up much of the boat's total length, this will be manageable.When all the standard frames are done, I'll start installing the keelson and other stringers to hold the structure firmly together, then proceed on the more complex ends.
 
So that's where the Bertrand stands this weekend. I will do another update when these square frames are completed and I've started in on the interesting challenge of stem & stern. Hopefully the wait won't be as long this time!
 

The Bertrand, version 2.0, is underway!
 

 
Above, you see a set of mid-hull frames assembled and laid out at the prototype spacing of about 15 scale inches. Astute observers may notice something different from earlier in this log: these frames are built at a 90 degree angle (floor to futtock), not canted outward. The more I compared my purchased plans to the original archeological drawings now in my possession, the more blatant errors I found. I've now pretty much abandoned those first plans and spent some time scanning and resizing the new drawings to 1:87 scale and hitting the reset button on pretty much everything involved with this project. Hence the delay in updating this log, along with a busy few weeks in real life. 
 
According to the actual archeological notes (from here on referred to as the Petsche plans after the leader of the excavation team), Bertrand very definitely had squared-off mid-hull frames, with angles only occurring at stem and stern. In other words, this plan view and the frames I built from it were totally wrong:
 

 
So I designed a new set of frame molds and have been busy mass-producing frames:
 

 
I do these eight at a time, pre-cutting the floors and futtocks on my trusty cutter (upper left), then assembling them around the wooden molds seen at right. These are pinned to a piece of foam board, holding everything in place. I pin a floor in place, dip each futtock in wood glue, then fit it in place along the side of the form, using another pin on each side. Then I use the cutter to create the tiny angle braces, smear some more glue across the joint, and use tweezers to install each angle brace on top. Below is a detail of several of these assemblies:
 

 
When these are dry, I use the cutter to lop a small 45 degree angle off each bilge corner, where a bilge plank will go. These areas were not rounded as on a sea-going vessel, but angular, which made construction much easier for the craftsmen assembling these boats in the American wilderness of the upper Ohio River. Note that the molds have a 45 degree angle cut out at the turn of the bilge. This is so I can glue the bilge together without anything sticking to the mold. The remainder of the frame is sufficient to hold the pieces at a proper 90 degree angle. Anything that sticks to the foam board is popped off with a flat knife blade and sanded smooth.
 
Here's an overhead view of my hull setup:
 

 
A copy of the inner hull plan is attached to the build board with double-sided tape. Several layers of wooden strips line both sides of the hull to provide consistent support for the frames (also attached with tape). The plans then have four thin strips of double-sided tape run on top, to hold the frames in place during assembly. I use wooden spacers to support each frame, keeping it at the proper distance from its neighbors and properly vertical. In these photos, I've removed some spacers temporarily so you can see more detail. I've used tape for everything to allow adjustment is necessary, and it works great. This jig was very much inspired by the Cairo build suggested earlier in this log (thanks, Ken!)
 
As each batch of 8 frames is ready, I add them to the hull jig. It takes 15-20 minutes to build 8 frames, then a few hours for the glue to dry. I basically do a batch any evening I have a short stretch of time to spare, and slowly but surely work my way toward the daunting total quantity needed. This means I don't get overwhelmed trying to do them all at once, or keep count. 
 
Once I reach the beginning of stem and stern curves, I will have to build the frames custom-in-place, but as the standard square frames make up much of the boat's total length, this will be manageable.When all the standard frames are done, I'll start installing the keelson and other stringers to hold the structure firmly together, then proceed on the more complex ends.
 
So that's where the Bertrand stands this weekend. I will do another update when these square frames are completed and I've started in on the interesting challenge of stem & stern. Hopefully the wait won't be as long this time!
 

The Bertrand, version 2.0, is underway!
 

 
Above, you see a set of mid-hull frames assembled and laid out at the prototype spacing of about 15 scale inches. Astute observers may notice something different from earlier in this log: these frames are built at a 90 degree angle (floor to futtock), not canted outward. The more I compared my purchased plans to the original archeological drawings now in my possession, the more blatant errors I found. I've now pretty much abandoned those first plans and spent some time scanning and resizing the new drawings to 1:87 scale and hitting the reset button on pretty much everything involved with this project. Hence the delay in updating this log, along with a busy few weeks in real life. 
 
According to the actual archeological notes (from here on referred to as the Petsche plans after the leader of the excavation team), Bertrand very definitely had squared-off mid-hull frames, with angles only occurring at stem and stern. In other words, this plan view and the frames I built from it were totally wrong:
 

 
So I designed a new set of frame molds and have been busy mass-producing frames:
 

 
I do these eight at a time, pre-cutting the floors and futtocks on my trusty cutter (upper left), then assembling them around the wooden molds seen at right. These are pinned to a piece of foam board, holding everything in place. I pin a floor in place, dip each futtock in wood glue, then fit it in place along the side of the form, using another pin on each side. Then I use the cutter to create the tiny angle braces, smear some more glue across the joint, and use tweezers to install each angle brace on top. Below is a detail of several of these assemblies:
 

 
When these are dry, I use the cutter to lop a small 45 degree angle off each bilge corner, where a bilge plank will go. These areas were not rounded as on a sea-going vessel, but angular, which made construction much easier for the craftsmen assembling these boats in the American wilderness of the upper Ohio River. Note that the molds have a 45 degree angle cut out at the turn of the bilge. This is so I can glue the bilge together without anything sticking to the mold. The remainder of the frame is sufficient to hold the pieces at a proper 90 degree angle. Anything that sticks to the foam board is popped off with a flat knife blade and sanded smooth.
 
Here's an overhead view of my hull setup:
 

 
A copy of the inner hull plan is attached to the build board with double-sided tape. Several layers of wooden strips line both sides of the hull to provide consistent support for the frames (also attached with tape). The plans then have four thin strips of double-sided tape run on top, to hold the frames in place during assembly. I use wooden spacers to support each frame, keeping it at the proper distance from its neighbors and properly vertical. In these photos, I've removed some spacers temporarily so you can see more detail. I've used tape for everything to allow adjustment is necessary, and it works great. This jig was very much inspired by the Cairo build suggested earlier in this log (thanks, Ken!)
 
As each batch of 8 frames is ready, I add them to the hull jig. It takes 15-20 minutes to build 8 frames, then a few hours for the glue to dry. I basically do a batch any evening I have a short stretch of time to spare, and slowly but surely work my way toward the daunting total quantity needed. This means I don't get overwhelmed trying to do them all at once, or keep count. 
 
Once I reach the beginning of stem and stern curves, I will have to build the frames custom-in-place, but as the standard square frames make up much of the boat's total length, this will be manageable.When all the standard frames are done, I'll start installing the keelson and other stringers to hold the structure firmly together, then proceed on the more complex ends.
 
So that's where the Bertrand stands this weekend. I will do another update when these square frames are completed and I've started in on the interesting challenge of stem & stern. Hopefully the wait won't be as long this time!