Tricky joints … and knees.

I returned to college on Monday, after a really good break. We’re supposed to finish the small boatbuilding module this week, so have all been pushing on, hoping to complete the fitting out of Deck Boat 1.

When I finished for the holiday, the three thwarts were fitted, and I was about to fit the side benches with that tricky stepped scarf-like joint.

After two weeks away to mull things over, I was clear in my mind how I would tackle the job. I started to work.

“I didn’t think we were going to have a stepped joint … we can do without it” said one instructor. “You could mitre the inner corner” enjoined another, who added: “it would be good to put a thumbnail rounding on the edges of these thwarts,” and then showed me how the thumbnail is done.

And we’re short of instructors!!!

Using a router, I nervously cut out the joint on the thwarts. Finishing off with a chisel, I then planed the bevel on the side bench.

Thwart (on left) and side bench, all ready for the original step to be cut for the stepped joint

I measured and marked out, then checked and re-checked. Had I got this right? With heart in mouth, I cut each mitre in turn. Relief, then jubilation as, with just a few ‘relief’ saw cuts, the joints came together tightly.

A relief cut, made with a very fine saw blade, and …
… it fits!

Bob’s advice had been both good and timely: the mitre to the inside corner of the joint, and the thumbnail rounding, have made all the different to the final result.

With the side benches fitting nicely, I glued up the joints with thickened epoxy resin. ‘Butt’ blocks cross the underside of the joints to give extra strength and support.

The finished ‘sternsheets’ construction of thwarts and side benches.

To strengthen the gunwale of the boat, including against side impact, thwart knees are being fitted.

Here are the two thwart knees I am making for the centre thwart. On Monday, I aim to finish them, fit them with roved copper nails ,and trim the tops level with the gunwale.

Some of these knees will be covering my carefully-made joints, leaving only that mitred section visible. Ah well, if invisible to others, at least I have the satisfaction of knowing that they’re a good fit!

Well, we haven’t managed to finish the fitting out of DB1 but, before the course ends in just six weeks, we do have some spare days left to finish off various projects. It would be great to complete this project.

I’ll keep you posted.