Bulkheads - Front
The Bulksheads are constructed from Cedar Strips glued to 5mm Plywood and encased in Glass.
The Port Hole and Port Mounting Holes are lined with thickened epoxy to prevent water contact with the wood.
Bulkheads - Rear
Undersize Cardboard was mounted in the Canoe at the Bulkhead Locations and the shape of the Hull transferred to the Cardboard to create a template.
The template was then used to cut the plywood backing. After the backing was hand fit in the Canoe the strips were attached.
A Deck Port will be mounted in the hole.
Bow Bulkhead
Bulkhead taped in place. Ready for Epoxy Fillet.
The apparent excess tape contains the thickened (brown color) epoxy in the Fillet area between Bulkhead & Hull.
During the Filleting process excess epoxy lands on the tape and can be later removed with the tape.
Stern Bulkhead
Bulkhead taped in place. Ready for Epoxy Fillet.
The thickness epoxy is applied with a syringe and then tooled with a Filleting Tool.
Bulkhead - Top View
The Fillet of thickened epoxy will be tooled and finished on both sides of the Bulkhead.
Deck Parts
The Deck is constructed of (3) 1/4" thick Mahoganny shapes.
Deck Assembly
Thickened Epoxy is applied to the top of the bottom section, bottom of the top section, and both sides of the Center Section.
Deck Fixture
The Deck is actually curved as it follows the Sheer Line on the Canoe.
The Sheer Line shape (at the Bow and Stern) was transferred to a template and Fixtures constructed.
The Deck Sections were clamped to the Fixture for 72 Hrs and the Deck took on the shape of the Sheer Line.
The Sheer Line was slightly different at the Bow & Stern thus (2) Fixtures were constructed.
Stern Deck Location
After Hand Fitting the Decks the mounting area is taped off to prevent excess epoxy from spilling onto the Gunwales and Hull.
Bow Deck Location
Thickened epoxy will be used to bond the Deck to the Gunwales.
Stern Deck Assembly
The Deck is mounted and clamped in place for 72 Hrs while the epoxy cures.
Bow Deck Assembly
Bow Deck Installed
Deck Installed and Sanded to matach Gunwale.
Stern Deck Installed
Bow Deck
Seal coat of epoxy applied to prevent air bubbles fro forming under glass.
Stern Deck
Seal coat of epoxy applied.
Bow Deck
Glass laid out and ready for epoxy. Note that the glass will wrap the Gunwale and the inside edge of the Deck for abrasion resistance.
Glass was applied to the underside of the Deck prior to install.
Stern Deck
Glass wet out with epoxy. Note the edges of the glass overhanging the corners.
Gunwale Glass
Fiberglass was wrapped around the Gunwales from the bottom of the Outwale to the bottom of the inwale (both Port & Starboard) from Deck to Deck.
Gunwale Glass
The two dozen openings located along the outer edge of the Inwales are Scuppers.
The Scuppers are necessary to permit the Inwale to bend Convex and fit the shape of the Canoe along the sheer line.
They are also used as tie downs for gear.
The Scuppers were coated with (3) coats of epoxy prior to Inwale installation in the Canoe.
Scupper Glass
The Scuppers were covered with glass and then cut out later with a drill and small series of rasps.
By covering them with glass the risk of epoxy dripping through the scuppers was eliminated.
In addition, it would have been a nightmare to try to cut the fiberglass cloth and fit around each scupper.
Finished Deck
This photo illustrates the beautiful color of the Mahogany Deck and detail in the tapered Inwales and Outwales to make the parts all fit together.
Note how the Inwale tapers from 3/4" to Zero along the length of the Deck.