Refit of the schooner CHARLIE by AON - Finished

[captainbob]

Good morning Druxey

YUP... you are absolutely correct (as usual )... it has to do with the round stock and a wandering bit.

I need a good flat surface and managed to accomplish it the very first time and since have not replicated it.

I am not prepared to throw in the towel just yet and purchase square stock... I'll give it another go

 

 

What I do is to chuck the drill shorter so only 3-5mm is sticking out of the chuck.  The short drill exposed is much stiffer and does not walk as much.

 

Bob

[AON]

Thank you Bob

 

My first (and successful) attempt was done with the drill twist on both bits exposed completely (full length)

My second (failed) attempt was similar

All successive trials were choked up as short as possible to minimize the buckling effect on the tiny thin column (drill) as I figured as you suggested it might give me more control.

 

Darn thing skips away on me!

My flattened surface isn't flat enough?

My guide dimple isn't deep enough?

I am not steady enough?

 

I am going to give it another go this weekend.

Make sure I am well rested and take my time.

 

Hope to have it mastered... must practise some mental Yoga before!

Edited October 31, 2014 by AON

[AON]

SATURDAY 01 November 2014

 

HORRAY!    I did it

I successfully repeated the stanchion drilling process

The problem was it needed parallel  flats on both sides to lay steady

 

I removed the jaws from my vise and clamped flats on both sides at once

Flipped it over to do the other end as one wire is two stanchions when cut in half.

 

This time I used a #66 drill bit, slightly smaller

 

I think I will only put in two handrail wires as three looks to be too busy

[AON]

Saturday 01 November 2014

 

Completed the base also

 

Rough cut the vee notch with my bandsaw then rasped, filed and sanded

Had to cut 1/8" off the longer aft post to have her berth level

 

I have planed and sanded the base after these photos

nothing is glued as yet

 

The oak looks fantastic... I think I'll stain it and paint the posts white

 

Very sturdy!

I am happy with this.

[Omega1234]

Hi Alan. Really nice, especially the view of the hull from the stern. You've really done a great job shaping the hull.

 

Well done.

[AON]

Thank you!

 

I was very concerned with the possibility of having taken too much off one side when shaping or ending up with a wiggly snake like surface.

It is not "perfect" but I believe it is because I know where the "issues" are.

I dare not shape it any further or my concerns will come true.

 

Stripped the jackets off the ends of the wires last night for the stanchions.

Going to clamp the flats, drill the holes, shape the tops and cut into two pieces today.

 

Thinking ahead to the rest of the deck and bowsprit.

 

[michael mott]

Good to see that you solved the stanchion issue. The hull does look very nice with the extra keel and the fairing.

 

Michael

[AON]

Sunday 02 November 2014

 

Managed to get all stanchions (and a few spares) ready to be drilled through.

 

First I punch marked the hole location with a nail I ground a sharp point on.

 

Then I drilled a dimple into the stanchion with a #66 bit in a pin vise so that when I go at it with my dremel the bit will not wander. 

 

I will start drilling them all through tomorrow night.

Edited November 3, 2014 by AON

[AON]

Monday 03 November 2014

 

Completed drilling all the stanchions

Had to scrap five halves as the holes were too close to the edge

Flattened new pieces and will drill them tonight.

 

Also started on a bow gunwhale/combing to assist in holding the bowsprit in place

Not much to look at/show as yet.  Just traced the outline onto scraps of maple.

Developing my plan of attack in my minds eye.

 

Also

The plaster wall lath my son is tearing out of his home was thought to be ash but in fact it has been found to be eastern hemlock.

I passed a short piece through my planer and edger last night and I am left with a beautiful finished piece 0.32" thick (8.1mm) x 1.37" wide (35mm)

It has got me as excited as the oak base had.

I think I'm in love.   

I'll be grabbing more of this from his wood pile before he burns it all!

[AON]

Had some time to kill this morning before I go to the doctor's office to get my flu shot so completed the outine on the addition for the bow and took some photos.

 

I will cut it out tonight or tomorrow and will scallop it to suit the bowsprit when that item is ready.

 

I also took a photo of the lathing material before and after planing so you can see what was revealed under 100 years of hanging on a wall under plaster.

Edited November 6, 2014 by AON

[AON]

Tuesday 04 November 2014

 

cut the shape with my scroll saw

lightly sanded

needs more shaping and a clearance hole for the bowsprit but here is the idea

 

by my calculations the bowsprit should be approximately 0.4666" dia and 4-1/2' extension beyond the bow

the dowel is 7/16" dia = 0.4375"

 

PS: forgot to mention the warts... I cut one piece backwards and had to start it all over

Edited November 5, 2014 by AON

[AON]

Progress may slow down as my working associate (salesman) brought in a few orders and it has me working overtime.

 

At least I can blame it on him this time.  

Edited November 9, 2014 by AON

[AON]

Sunday 09 November 2014

 

Redoing the Samson Post as I decided the first attempt wasn't good enough

Also clamped down the bow cowling  or faux gunwhale in readiness to drill the bowsprit clearance hole

[AON]

Friday 14 November 14

 

Managed to recut the Samson Post (still requires some shaping in the top 1/3)

 - Dry fitted with Bowsprit

 - Set up to measure angle (8°) of assembly so I can set up the bow cowling angle for drilling the bowsprit hole

 

Also did some practise cutting on my wood lathe for the ships wheel shaping

 - Turn round

 - Cut out centre hub

 - Mark part line

 

I will finish this one to make sure I am happy with it and then do the real one that has been predrilled for the spokes

As this looks like a good port hole cover for the cabin I may do the same thing with smaller dowelling

 

Hope to accomplish considerably more this weekend.

Edited November 14, 2014 by AON

[AON]

Saturday 15 November 2014

 

Today I find myself a year older but not one iota smarter!

 

I completed my test piece on the lathe and was very happy with the results so I decided to do the ships wheel.  I set my predrilled doweling up and began cutting away.

The centre hub, a crucial part of the wheel, vaporized in front of my eyes.  Never giving in I decided I could make a new hub so I carried on.  Completed the outer part and set it against the wheel gear house.

Decided it was too thick so I sanded the two faces to thin it down.  This is when it happened.

I thought I had learned the lesson of knowing when to say ‘when’….. it was now too thin.  Into the trash bin!  Time for a ‘do over’.

 

I started on the bowsprit cowling.  Set up the piece on my drill press at what I determined to actually be closer to 6-1/2° angle (4 separate readings) and plunged into it.

This, to my surprise, worked out okay (photos below)

I will eventually drill, pin and glue this to the deck and then sand the outside face to blend in to the hull.

 

I then worked on the Bowsprit Bitts and Samson Post assembly.  Having completed them, dry fitting to check I moved on to shaping the bowsprit (photos below)

 

I mounted the bowsprit to my lathe and turned/tapered it to rough shape.  I then finished it on the lathe with sand paper.  Dry fit it all together and found I needed a wee bit of shaping on the cowling.  Now I am happy.

 

Went to Michael’s (hobby & craft store) and bought some brushes and paint (primer, black, dark red and white).  Also picked up a tube of wood stain at Canadian Tire which I am hoping will work better on the cabin roofs.

 

Once I have the masts located, all holes drilled and the deck sanded it will get a good cleaning and then a paint job.  But for now I need to redo the ships wheel and make four port holes for the cabin.

Edited November 16, 2014 by AON

[druxey]

Quite the clamp and drilling set-up you had there! Ingenuity knows no limits....

[AON]

Thank you Druxey

It doesn't look like much but it is making good use of scrap pieces and surprisingly did the job

I admit I was concerned it might fly apart.

[AON]

Sunday 16 November 2014  (Part 1)

 

Drilled and dry pinned the cowling to the bow

Sanded to finish shape

Edited November 17, 2014 by AON

[AON]

Sunday 16 November 2014  (Part 2)

 

Made a new ships wheel

Re-drilled the spoke holes

Turned the wheel on the lathe and once again the hub vaporized

This time I saw it happen.  The holes (thru what would be the hub) remove all structural integrity in the material and it tears apart.

Did my final cut to part it from the dowel on the band saw

Cut a smaller dowel to make the hub

Of course it was not “square” so I drilled a shallow pocket hole (big enough to fit the hub into) in a piece of scrap and used it to hold the hub square against the disc sander to true it up.

Cut my spokes to length

Installed them in my drill press chuck and used small files to shape the handles.

(I should be wearing safety glasses but it was so tiny I couldn’t see what I was doing… I had to look over my lenses to focus… getting old sucks)

Dry fitted and remarked the shorter lengths for the spokes.

Drilled another pocket holder and disc sanded the spokes square to length

Reassembled and glued (small dabs) from the backside.

Drilled and installed a brass pin nail as the hub pin.

Edited November 20, 2014 by AON

[AON]

Sunday 16 November 2014  (Part 3)

 

Worked on the masts

Calculated (by ratios from an image) the scale length and diameter of the masts

5/8” diameter, 14.1” and 15.5” long

Calculated the rough locations and set angle of the masts

Set the hull up to my drill press at 3° angle and drilled two ½” diameter holes for the masts to be stepped into.

Found some 5/8” diameter dowels and cut them 4 inches longer and mounted them in the lathe

Turned the deck stepped fit portion 0.510”+ diameter to fit (Tapered the lead end to assist assembly)

Turned the top end to +/- 0.400” diameter

Tapered the length between and sanded in place on the lathe.

Dry fit into deck (not driven in as I would not get them apart again) to check.

I am happy with these.

 

I have not made the cabin port hole pieces yet.

[AON]

Further progress will come to a crawl as I'll be back to working overtime this week.

[kees de mol]

Nice build with that solid hull. It must have been a lot of work to carve it out. Looking forward to your next update.

 

Regards, Kees

[AON]

Saturday 22 November 2014

 

(PART 1)

Completed the handrail stanchions

- drilled

- deburred

- reclamped in vise to straighten face and turned 90° to straighten edge

- drilled again

- polished with wire brush wheel on dremel  with my dremel clamped in a vise

 

I also sanded the deck and filled cracks and dents

It will need another sanding

Edited November 24, 2014 by AON

[AON]

PART 2

 

I couldn't take it anymore!

 

I've tried to ignore it but it was sticking out like a sore thumb

 

I tried convincing myself that it was one of the few things the gentleman had done and I should leave it alone.... but then I talked myself into believing he will likely never notice.  I also believe it is easier to get forgiveness than permission so it did it!

 

I cut the cabin height down to get it more into a proper scale

Of course this meant redoing the door.

Edited November 24, 2014 by AON

[Omega1234]

Hi Alan. I was thinking the very same thing all along, about the cabin height. I'm glad that you lowered the height, but, I also share your sentiments in hesitating to do it.

 

Should look heaps more scale-like in appearance now.

 

Well done and all the best!

Edited November 23, 2014 by Omega1234

[captainbob]

He will probably think it looks better and never know why.

 

Bob

[AON]

Sunday 23 November 2014

 

Part 1

 

Worked on the cabin port hole rings.

My inspiration was a garden hose snap on O-ring as it seemed the perfect size.

 

After numerous attempts with the lathe I had to come up with a plan B

- set up dowel in clamp, squared to drill bit and drill hole though the end (the tough part was centering it)

- cut four pieces about twice as long as needed on the band saw

- prepared a "holder" and square up ends and thinned to size on disc sander

[AON]

Part 2

 

Went back to the masts and started on the cross tree assemblies

- marked the location of the support cheeks

- rasped, filed and squared off cheek pocket with a knife

- made a stiff paper template of the cheek and fit it to the pockets

- transferred shape to wood and cut out with the scroll saw

- sanded to shape

- dry fit and finally glued and clamped in place to set overnight

 

I then worked on the cross trees

4 trial pieces (you can call them errors   ) before I got anything near what I was attempting.

 

Trestle trees will be next

Edited November 24, 2014 by AON

[Omega1234]

Hi Alan. The amount of work that you're putting into this ship is magical. She's going to look fantastic. Your friend and his father should be extremely grateful.

 

Well done!

[AON]

Thank you everyone for the encouraging words and votes of confidence in my drastic action with the cabin height

 

I have pieces of plastic to use as window glass for the port holes and am thinking of drilling four holes through the cabin bulkhead, countersinking slightly to set the faux glass in, white washing the inside of the cabin so if looked into it is a bit brighter.

 

Monday 24 November 2014

 

- Drilled and pinned the cheeks to the masts with a slight interference fit (no glue) so I won't have to worry about this falling apart

- cut the pins off flush and lightly sanded

 

- cut and sanded the trestle tree pieces

 

Tuesday

since I am up early this morning I may as well go do another sanding of the hull as painting her will happen soon

Edited November 25, 2014 by AON