Attaching the Deck

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<td valign="top" width=190 BGCOLOR="#A6CAF0" TEXT="#080000"> <div> <A HREF="index.htm" TARGET="_top" TITLE="Building the Chesapeake 16"><U>Home</U></A></div> <div> <A HREF="id35.htm" TARGET="_top" TITLE="Choosing and Ordering"><U>Choosing and Ordering</U></A></div> <div> <A HREF="id38.htm" TARGET="_top" TITLE="Preparing and Unpacking"><U>Preparing and Unpacking</U></A></div> <div> <A HREF="id43.htm" TARGET="_top" TITLE="Gluing the Scarf Joints"><U>Gluing the Scarf Joints</U></A></div> <div> <A HREF="id46.htm" TARGET="_top" TITLE="Screwing up Scarf Joints"><U>Screwing up Scarf Joints</U></A></div> <div> <A HREF="id47.htm" TARGET="_top" TITLE="Gluing Sheer Clamps"><U>Gluing Sheer Clamps</U></A></div> <div> <A HREF="id50.htm" TARGET="_top" TITLE="Stitching the Hull"><U>Stitching the Hull</U></A></div> <div> <A HREF="id52.htm" TARGET="_top" TITLE="Filleting"><U>Filleting</U></A></div> <div> <A HREF="id53.htm" TARGET="_top" TITLE="Fiberglassing Inside"><U>Fiberglassing Inside</U></A></div> <div> <A HREF="id54.htm" TARGET="_top" TITLE="Installing the Bulkheads"><U>Installing the Bulkheads</U></A></div> <div> <A HREF="id56.htm" TARGET="_top" TITLE="Prepping Outside"><U>Prepping Outside</U></A></div> <div> <A HREF="id57.htm" TARGET="_top" TITLE="Fiberglassing Outside"><U>Fiberglassing Outside</U></A></div> <div> <A HREF="id61.htm" TARGET="_top" TITLE="Planing the Sheer Clamps"><U>Planing the Sheer Clamps</U></A></div> <div> <A HREF="id62.htm" TARGET="_top" TITLE="Installing Deck Beams"><U>Installing Deck Beams</U></A></div> <div> <B>Attaching the Deck</b></div> <div> <A HREF="id63.htm" TARGET="_top" TITLE="Trimming the Deck"><U>Trimming the Deck</U></A></div> <div> <A HREF="id64.htm" TARGET="_top" TITLE="Doing the End Pours"><U>Doing the End Pours</U></A></div> <div> <A HREF="id66.htm" TARGET="_top" TITLE="Installing the Coaming"><U>Installing the Coaming</U></A></div> <div> <A HREF="id67.htm" TARGET="_top" TITLE="Sealing the Deck"><U>Sealing the Deck</U></A></div> <div> <A HREF="id68.htm" TARGET="_top" TITLE="Varnishing"><U>Varnishing</U></A></div> <div> <A HREF="id72.htm" TARGET="_top" TITLE="Outfitting"><U>Outfitting</U></A></div> <div> <A HREF="id73.htm" TARGET="_top" TITLE="Launching"><U>Launching</U></A></div> <div> <A HREF="id75.htm" TARGET="_top" TITLE="Launching Boat 2"><U>Launching Boat #2</U></A></div> <bR> </td> <td valign="top" height=355 BGCOLOR="#FFFFFF" TEXT="#080000"> <div> Step 14:  Attaching the Deck</div> <bR> <div> After much preparation, it was finally time to install the deck.  Before proceeding though I had to attach a small section to the bow of the deck using a scarf joint and then coat the inside of both deck pieces with unthickened epoxy to seal it.</div> <bR> <div> Then it was really time to attach the deck.  First I laid the two deck panels (forward and aft) down on top of the boat to get some idea of placement.  I marked on the sheer clamps where the bottom panel needed to go:</div> <div> <IMG SRC="210a2d80.jpg" border=0 width="162" height="216" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> I attached the aft deck panel first.  I applied unthickened epoxy to the bottom of the deck and thickened epoxy to the sheer clamps, bulkhead, and top edge of the hull.  Next I positioned the deck panel on the boat and clamped it down using both spring clamps and a webbing strap clamp that came in very useful throughout the process:  </div> <div> <IMG SRC="1efd09c0.jpg" border=0 width="208" height="156" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> The deck does not want to curve by itself so it has to be nailed into position so that the epoxy has time to dry.  The brass nails came with the kit:</div> <div> <IMG SRC="21295700.jpg" border=0 width="149" height="112" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> The instructions didn't say to do so but I decided to drill pilot holes for the nails to go into.  I felt that I would have an easier job nailing them all in nice straight line and that there would be less chance of the sheer clamp splitting (which would have been a disaster at this stage in the game).  I cut out a template that allowed me to consistently find the middle of the sheer clamp and used that when figuring out where to drill each hole.</div> <div> <IMG SRC="217cd110.jpg" border=0 width="205" height="273" ALIGN="BOTTOM" HSPACE="0" VSPACE="0">   <IMG SRC="21609c70.jpg" border=0 width="265" height="199" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> So, I worked my way back from the bulkhead, alternating sides and doing about two or three nails at a time.  I readjusted my strap clamp every few nails so that the part I was working on was always squeezed in tightly.  After I had finished the aft panel I did the forward one, starting at the deck beam and moving forward and then back toward the cockpit.  </div> <bR> <div> I left some overlap between the two panels in the middle where they met so that I could make a butt joint there.  Here is what it looked like before I made the butt joint.</div> <div> <IMG SRC="219d49f0.jpg" border=0 width="212" height="159" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> To make the two fit perfectly together I just cut through the plywood of the forward panel right along the line of the aft panel using a shop knife.  It took quite a few passes but eventually cut a nice line that fit into the aft panel perfectly:</div> <div> <IMG SRC="21bbaf80.jpg" border=0 width="186" height="248" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> Next, I glued  2" by 3" pieces of plywood on the inside of the butt joints to brace them and clamped them in place:</div> <div> <IMG SRC="21de5ac0.jpg" border=0 width="229" height="172" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> Then, I flipped the boat over so that any drips would not run down the hull.  As you can see below the deck panels are cut about an inch too big all around.  This allows for some error when attaching the deck.  After the glue is dry I will cut it off with a saber saw and plane or sand it flush.  After I flipped the boat I saw that because my planing as not absolutely perfect, there were some gaps between the top edge of the side panels and the deck.  To correct this I mixed up some thickened epoxy and spread it into any gaps before leaving it to dry. </div> <div> <IMG SRC="221e4300.jpg" border=0 width="228" height="304" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <bR> <div> <A HREF="id63.htm" TARGET="_top" TITLE="Trimming the Deck"><U>Click here to continue.</U></A></div> <bR> <bR> <div> This website is a labor of love and I never expected anything in return.  But if you want to show your appreciation while also helping the environment, then <A HREF="http://www.amazon.com/exec/obidos/redirect-home/buildingthe0b-20" TARGET="_top" TITLE="http://www.amazon.com/exec/obidos/redire"><U>click through this link here to get to amazon.com</U></A> the next time you plan on shopping there anyway.  I will get a commission of 2.5-10% through their "associates program" and will donate 50% of that to <A HREF="http://www.sierraclub.org" TARGET="_top" TITLE="http://www.sierraclub.org"><U>the Sierra Club</U></A>.  Thanks, Tim</div> <bR> <bR> <bR> <bR> <bR> <bR> <bR> <bR> <bR> <bR> <div>  <IMG SRC="/bin/counter/id58.htm">  </div> <bR> <bR> <bR> <bR> <div>   <div align="center"> <div style="width:128; padding:2px; border:1px solid #000000; background-color:#f9f9f9; color:#000000; font:normal normal bold 11px verdana; text-decoration:none"> Visitors:  <script language="JavaScript" type="text/javascript" src="http://pub3.bravenet.com/counter/code.php?id=327672&usernum=196533157&cpv=2&bc=000000&bw=1"></script>  </div></div>   total page-views for the whole site since July 17, 2000.</div> </td> </tr></table></body>