Now I am in trouble

Well it took a while to get started but I am under way. My wife bought me plans for the Arthur Armstrong Broadbill for my 40th birthday. Currently I have been on Medicare for 10 years.

In 2014 Tom Schlberg and Steve Sanford responded to my queries giving helpful advice. It took some time to find free mahogany and then find marine grade plywood. But now we are off to the races!

I have all the pieces for the frames cut out and was ready to begin glue up. Did a search for what to use for epoxy fillers and saw a discussion about using sawdust from cutting/planing. There were several comments about how fine the saw dust needed to be for glue up vs fairing. So I took my sawdust from planning the rough boards up to the kitchen and used my wife's coffee grinder to refine them to the texture of expresso.
I thought I had cleaned it out.
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Bruce

I'm looking forward to your build. My first build was going to be an Armstrong from a kit back when I was in college. But the shippers busted the crate open spilling pieces from NY to AL. I got my money back and sat on the boat building bug for 10 years. Please keep up informed and as always, post some pics!

Eric
 
Good for you Bruce. I built one back in 85, I think. A friend still hunts out of it on the Cape. My plans look a little different from yours, but the pattern transfer concept appears to be the same. I used Weldwood (resorcinol) glue on mine with no filler, although my plans called for plywood plates at joints which I don't see on your frame. Maybe you haven't made the plates yet? It's a relatively simple, stress free build. Best of luck with it.
 
Bruce Brooks said:
Did a search for what to use for epoxy fillers and saw a discussion about using sawdust from cutting/planing. There were several comments about how fine the saw dust needed to be for glue up vs fairing.

Bruce,

I've used reclaimed wood dust/shavings and yes it needs run through a flour sifter, using only the fines that are able to go through the screen. I've also used both cab-o-sil and phenolic microballoons for fillers. All three choices will work but I prefer the purchased products. I find those more consistent and easier to blend into the epoxy mix.

Plus they are cheaper than a new coffee grinder. [sly]

Good luck with your build.
 
That looks great, I hope you continue to post.

As for the flour, anything you can do to get a uniform is helpful. The absolute last thing you want it larger particles in the mix.

If you look carefully, you can find wood flour premade for very reasonable, you are not going to use that many pounds. You can also use regular flour from what I hear.
 
tod osier said:
That looks great, I hope you continue to post.

As for the flour, anything you can do to get a uniform is helpful. The absolute last thing you want it larger particles in the mix.

If you look carefully, you can find wood flour premade for very reasonable, you are not going to use that many pounds. You can also use regular flour from what I hear.

I have heard cooking flour works too although I've never tried it. Talc is another filler you might consider if you are trying to minimize costs. I'd probably research these two a little but suspect one or both will do.
 
Cooking flour does work, and makes for a very nice working texture. Sam Told me this when I needed a mid season repair and out of wood flour.

As Tod stated. The last thing you want is a big chip in the peanut butter...or frosting!
 
Well things were running along smoothly here in my "shelter-in-place" world. Got all my pieces for the frames cut out and labeled.




I dry fitted the pieces for my first frame member and everything looked good.




So I proceeded to "wet" the joints in preparation for the glue up and assembly.




Started the glue up. I had pre-drilled the holes for the nails in the bottom and side gussets. With the frame members in place I laid the gussets on top and began to nail them in place. Once I finished that I noticed some "overhang" from the gussets that previously wasn't there. After letting the epoxy cure for a bit I turned over the assembly and was stabbed in the heart. Horrendous gaps!




Where did I go wrong? Is this just kindling for the fireplace or can it be salvaged?
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Bruce Brooks said:
Well things were running along smoothly here in my "shelter-in-place" world. Got all my pieces for the frames cut out and labeled.




I dry fitted the pieces for my first frame member and everything looked good.




So I proceeded to "wet" the joints in preparation for the glue up and assembly.




Started the glue up. I had pre-drilled the holes for the nails in the bottom and side gussets. With the frame members in place I laid the gussets on top and began to nail them in place. Once I finished that I noticed some "overhang" from the gussets that previously wasn't there. After letting the epoxy cure for a bit I turned over the assembly and was stabbed in the heart. Horrendous gaps!




Where did I go wrong? Is this just kindling for the fireplace or can it be salvaged?

Cant see pictures
 
Well it has been a minute since I last posted but progress is being made. The plans came with a manual to explain the assembly process. I have been reading them for twenty years and still had questions. So I called Clark Craft only to find that yes they still sell the plans but the people who cut out the pieces for the "kits" had been let go. The owner had no idea how the assembly went together.

This left me in a quandary. A lot of trial and error, more study of the plans and manual, and wasted wood.

Below are photos of the current state of assembly.
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