TALES FROM THE CRYPT: The Resurrection of a Gunning Coffin

Steve Sanford

Well-known member
Good morning, All~


After sending my only gunning coffin down to Long Island in December to a new owner, by coincidence a local friend came by with one early in the New Year:


View attachment 1 Coffin - vertical oblique.JPG



I do not recall how he described it. He was coming by for some Basswood and I told him I'd be happy to provide some advice on getting whatever it was ready -to-hunt by next season. As it happens, my friend had no awareness of "Sanford Gunning Coffins/Boxes".....


View attachment 2 Coffin Box in SSWA Newsletter 1984 INSET.jpg



For those of you who have not heard the story....


After making my first one for the 1981 season, I posted plans and instructions in the newsletter of the South Shore Waterfowlers Ass'n (on Long Island). They soon made their way to the New Jersey Waterfowlers - who first posted them on the web. In fact, they made their way here to duckboats.net long before I became a member in 2013.



View attachment 3 Coffin Box Plans 1981.jpg

BTW: Both the back story and how-to-build are on my website:


https://stevenjaysanford.com/sanford-gunning-box-2/



https://stevenjaysanford.com/sanford-gunning-box/




It was obvious at a glance that this coffin had been built from my plans - but departed from them in several ways.


Here is the 2019 coffin I had just sent off to Long Island.



View attachment 3B GCCanvas - In the barn for now - straightened.JPG



On the project box, note that the canvas offers a very small opening. I wonder if the gunner rested on top of the canvas. It looks to me like it would be tough to get in and out of that narrow slot.


View attachment 4 Canvas - narrow opening.JPG



Another difference was the transom. I build mine with a raked transom - on which the soles of my boots rest. This transom is vertical.


Note, too, that a thin batten covers the canvas along the gunwale.



View attachment 5 sm Vertical stern transom.JPG



This transom is framed plywood. I use 3/4-inch Pine or Cypress. And, I usually cut a slot in it to serve as a lifting handle.


View attachment 6 Transom framing.JPG



An interesting feature was the "signature" preserved "under 'glass" on the bottom. This - and the assertion that it had once been owned by a certain NFL player helped me track down its provenance - and subsequent journey through several gunners as it made its way north over the decades.



View attachment 7 Keep the Faith - Mickey Shuler.JPG



In any event - although it clearly needed new canvas - it looked like the box itself was sound. It remained in my shop for the next month or so.


Stay tuned,


SJS



 
Last edited:
Part 2: Rehabbing the box


After removing the canvas, we inspected the box more carefully - and began the rehab. The first task was to install rubrails - to stiffen the sides and to give something into which the canvas could be stapled. These rails can be attached to the inside of the box or outside. I have done it both ways but prefer the outside "rubrail" approach - so I can later drive staples through the canvas into a softwood (rather than 'glassed plywood). I used clear White Pine, fastened from the inside with s/s panhead screws. I then faired off the top of the edges with an electric plane followed by a belt sander. The outer edges of the rails are rounded over with a router - prior to installation.



View attachment 21 Proud edges planed and sanded flush with rubrails.JPG



We had not noticed that the bow transom was "irregular" until the canvas was off.


Note the we also bored a rounded notch in the stem - to hold the new bow in place.



View attachment 22 Bow Transom - comparison.JPG



I took the opportunity to replace the upper half of the bow transom with a radiused and beveled "dutchman". Biscuits and thickened epoxy provided sufficient strength.



View attachment 23 Bow Transom - glue joint and biscuits.JPG



And the new wood got new 'glass - set in epoxy.


View attachment 24 Bow transom - glassed and faired.JPG



Here's the box with its first coat of paint - Parker's Marsh Grass.


View attachment 25 Bow Transom and Box painted A.JPG



My original bows were laminated Oak - back when I used Weldwood instead of epoxy. Later I switched to bent conduit. The dramatic asymmetry in the Oak bow is hard to understand.....



View attachment 26 Bow Comparison.JPG



We added this filler onto the stem to get a better angle for the headrest. One's eyes should be gazing comfortably at the decoys when relaxed.


View attachment 27 Filler on stem knee.JPG



Here is the new bow installed.


View attachment 28 Coffin - bow installed.JPG



Instead of cutting a slot in the transom for lift, we decided to go with nylon webbing. Instead of drilling holes through it, it is stronger to melt the holes with a heated awl.


View attachment 29 Coffin - melting webbing.JPG



The doubled webbing is fastened with brass machine screws - and s/s fender washers inside and out.


View attachment 30 Coffin - stern transom loop handle.JPG



Now for the canvas.....


SJS



 
Part 3: The canvas


In many ways, the canvas is one of the principal features that distinguishes these coffins from traditional coffins - which had either wooden decks - or were open to the skies. Their flexibility allows ease of getting in and out - and helps the "thatch" survives the indignities of a long season. And - when fully thatched - the gunner is invisible.



We fitted the 3 pieces of canvas (Sunbrella Tan) - and sew as we go. Here the owner is installing some of the 2 dozen grommets needed to hold the 2 rows of 1/4-inch shock cord in place.



View attachment 31 - Installing grommets SQUARE.JPG



My earliest coffins used a single row of sewn loops to hold Salt Hay bundles. Now I lash bundles to the shock cord with twine. The added movement of the shock cord helps to keep the thatch intact.


Padded headrests are a newer feature, too. Because they are padded, they must be fastened before installing the canvas. The headrest is bolted through the stem.

A drawstring - tarred nylon decoy line - sewn into a hem along the entire interior edge of the canvas pulls the canvas taut - especially at the head where it just barely protrudes aft of the bow.


View attachment 32 - Headrest padded.JPG



The drawstring is tied off at the stern transom.



View attachment 33 - Drawstring and shock cord.JPG



The shock cord disappears 'neath the canvas a few times as it encircles the box.



View attachment 34 - Shock cord and grommets.JPG



Figure-eight knots are used to tie off the shock cord inside the stern transom.


View attachment 35- Coffin from foot closer.JPG



A heavier webbing was used for the 'midships handles. We set the box on a single sawhorse to find where it balances. These loops are useful when manhandling the box before and after the hunt.


View attachment 36 - Shock cord and web handles.JPG



Out in the weather! The proud owner still needs to do a bit of painting - then lash on a hundred or so bunches of his favorite marsh plants next Fall.


View attachment 37 - Proud Owner Jones.JPG



All the best,


SJS



 
Great resto Steve. Guessing from last pic this bx must have been built to 8' long instead of the 74" called for in your plans. Any idea of weight completed in that lenght?
 
Good morning, Roy~


Funny you should ask about the weight. Although my deer scale is handy in the shop, I was plumb out of gas when we finished up yesterday. 'twas all I could do to get a few photos. Nevertheless, I am confident it was in the mid-30srange - typical of these boxes.


All the best,


SJS





 
Roy~


Yes - light weight was always a key design criterion. On my earliest boxes - when the "standard" 'glass cloth was 10 ounce, I 'glassed only the bottom and taped the chines. Since then, I use 6 or 7.5 ounce cloth and protect the whole exterior.


Years ago a bayman friend 'glassed his inside and out - maybe with mat - so it would be "bullet-proof" - but paid the price with unneeded weight.


Some have built them via stitch-n-tape - and probably save a little bit more.



All the best,


SJS





 
AS always
Great rebuild..

If one was to build a coffin how many hours from start to finish?
I do not need one but I need to build one lol
 
Bill~


The short answer is probably between 12 and 16 hours all told.


Back in the day, we "mass-produced" a couple of times. 3 or 4 of us gathered in my basement shop and assembled 5 boxes in a single day. Each box still needed its 'glass work, paint and canvas. The big savings is in being able to saw out the bottom and sides 5 at a time by stacking the plywood. And, making any of the other pieces in batches speeds the process, too.


I still need to replace my original plans with the only real change I've made in almost 40 years: I broadened the forward end of the floor by a few inches. It gives a bit more shoulder room but mostly makes assembly easier because the bend in the chine logs is a bit gentler.


All the best,


SJS

 
Now I have an excuse for not building one,
I AM WAITING FOR THE REVISED PLANS
thanks,

Steve Sanford said:
Bill~


The short answer is probably between 12 and 16 hours all told.


Back in the day, we "mass-produced" a couple of times. 3 or 4 of us gathered in my basement shop and assembled 5 boxes in a single day. Each box still needed its 'glass work, paint and canvas. The big savings is in being able to saw out the bottom and sides 5 at a time by stacking the plywood. And, making any of the other pieces in batches speeds the process, too.


I still need to replace my original plans with the only real change I've made in almost 40 years: I broadened the forward end of the floor by a few inches. It gives a bit more shoulder room but mostly makes assembly easier because the bend in the chine logs is a bit gentler.


All the best,


SJS
 
I am really convinced that I need to build 2 of them to get me back in the saltmarsh game. I regret storing the 2 we made together outside, although by this time they might have deteriorated anyway. The plywood delaminated and the canvas is rough. One was sized to me and the other more generic for a guest. They nestled in the boat opposite each other perfectly for trailering and as you well know towed them out to a spot. I love your idea for the converted sunfish or mini-fish as well but the coffins are more do-able. I'd tow that as well but would have to car top that one. I'm waiting on the new plans as well.
 
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