The building process

Strongback

The strongback is the building base for the boat, on which the station moulds for the hull shape are mounted. It is basically a rectangular wooden frame, with legs to bring it up from the floor. It is very important that it is perfectly square, reinforced  for stability and accurately horizontal.

For the boat sizes we would normally build, strongbacks are already available in our workshop.

Moulds

The moulds define the shape of the hull, the cross sections. They are used only for constructing the hull, which is built upside down and are removed when the hull is completed and turned over. The moulds are made of plywood and mounted at pre-defined intervals on the strongback. It is crucial that they are very accurately made and mounted (we strive for a tolerance of within one millimeter), and fixed so they cannot shift position during the build.

Like the strongback, for boat models we repeatedly build the moulds will already be available in the workshop, as they can be reused.

Backbone of the boat

Stem, keel and transom are made, mounted on the moulds, and shaped to take the planking

Planking the hull

The hull planks - the strakes are made, mounted on the moulds, and shaped to adjust to each other.

Interior completion

After sanding and preparing the inside of the hull, the frames are mounted. Then comes making, fitting and painting bulkheads, gunwales, centreboard case, seats and thwarts, floors and other details.

Turning the hull over

After sanding and epoxying the hull's outside, the hull is loosened from the strongback and moulds, and turned the right way up.

Mast and spars, rudder and centerboard

In between the previous tasks, when glue and paint is drying, there might be time to make these.

Painting and fittings

Sanding, fairing and painting is a time consuming process, with several layers of base coating and paint. We like to use 2 or 3 layers of epoxy for impregnating the wood, and as a hard base coat.

Some parts, like mast, seats and floor are only coated with several layers of oil.

The final job is mounting all the fittings and rigging.

Foto by Vincent and Esger van der Post

Foto by Vincent and Esger van der Post