D12 from a kit
Posted: Fri Apr 10, 2015 1:19 pm
Posted for Fred H.
12 Foot Dory Building Log
Hello to anyone who wants to read about my experience with the 12 Foot Dory. I will be posting my progress, and I will try to express a reasonable sequence of steps for others who are about to start.
I ordered the CNC kit, the epoxy resin kit, the sail, and the plans. All these come at different times, and the CNC kit needed to be picked up at a depot run by the freight company. I was able to place the kit on top of my Subaru Forester over two 2x4s lashed to the top rails. I tied it down with bunji cords. The freight company (Old Dominion in my case) lifted the kit onto my car with a forklift, but if I had to, I could have lifted it up there by myself. Jacques mentions the pack of drawings included with the kit. I could not find mine. Perhaps it got torn off in transit. At any rate, when you get the kit you should check for it, and if it is not there request it by email. I drove slowly so as to avoid wind getting under the package and sailing it.
Step 1 Unpacking the CNC Kit
Tools:
Dremel or fine-toothed keyhole saw
Sanding block and sandpaper (used is OK, grit is not that important)
Moist rag
Respirator if you are sensitive to sawdust
I was feeling like it was Christmas morning, and I really wanted to just get going on the kit. So I just opened up the kit, put the cardboard aside for use as floor covering, because I have an uneven concrete floor in my workspace, and I think the large sheets of cardboard will help me, and I removed the sheets of marine grade plywood that have been routed with the parts. In my case there was one thick sheet and two thin sheets. I carefully cut the tabs that hold the pieces in the sheets. I used a Dremel, and I had to adjust the speed so that I didn't cut too fast and make a cut into someplace I don't want to cut. I cut out each piece, and I piled them or stood them in a safe place. Then I went over the edge of each piece lightly with the sandpaper to get the splinters off and smooth the parts where the tabs had been, and I wiped them with the moist cloth to get the dust off.
Step 2 Reading and Understanding the Drawings
My Drawings came together with the Resin Kit in a separate shipment. It took me a while to understand what was what. Important things to remember are that:
a) the parts of the CNC Kit are slightly different from the parts described in the main set of drawings for the Dory. So it is very important to have the CNC Drawings together with the Main Drawings. You can get the CNC Drawings bay asking by email if you can't find yours;
b) the Main Drawings describe more than one option of the boat;
c) some parts are not provided in the CNC kit – I will need to procure some materials to make these parts, but the cost is minimal. I'm going to go with Douglas fir lumber (Jacques, please tell me if I'm wrong!)
In my case, after reading the drawings and emailing with Jacques, I have learned the following regarding my CNC parts (again Jaques, if I am wrong, please comment):
The bottom of the boat is comprised of 3 pieces: 1) the bow and most of the rest of the bottom, 2) the stern portion of the bottom, and 3) a butt board to attach 1) and 2).
Each side of the boat ("frame") is also comprised of 3 pieces: 2 lengths and 1 butt board each, and the butt board is 14 1/2 in. by 6 in. This size is not described anywhere in the drawings.
The mast partner and aft thwart cut from the thick plywood are not cut to the exact size (these are trapezoidal pieces of identical dimensions).
Before starting the connecting of the frame sides and the bottom, I am going to mark each piece to be certain I understand where it is supposed to be used. I cannot emphasize how important it was to read the drawings, and envision the boat that I want to make, and what steps I will do it in.