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09.09.2020
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Stitch-and-Glue Boatbuilding: How to Build Kayaks and Other Small Boats. Chris Kulczycki. out of 5 stars � Sam Devlin has elevated stitch-and-glue boatbuilding to an artform, and his graceful designs have attracted the attention of backyard builders across the country. Here is all you need to know to build the boat of your dreams, whether it's a 7-foot dinghy or a foot power cruiser. Devlin's Boatbuilding: How to Build Stitch And Glue Boat Building Tips Song Any Boat the Stitch-and-Glue Way shares the wisdom of his 16 years of experience designing, building, and helping others build his fleet of small sail- and powerboats. It's all here, from choosing a design and setting up shop to painting the finished hull and launch. Stitch and glue is a simple boat building method which uses plywood panels stitched together, usually with copper wire, and glued together with epoxy resin. This type of construction can eliminate much of the need for frames or ribs. Plywood panels are cut to shape and stitched together to form an accurate hull shape without the need for forms or special tools. This technique is also called "tack and tape", or "stitch and tape". Seams are reinforced with fiberglass tape and thickened epoxy. Home Boat Design Forums > Construction > Materials >. Stitch & Glue Questions. Discussion in 'Materials' started by ken.H, Jul 19, Page 1 of 2.� I have been doing research on stitch and glue building and design, Devlin's and The new instant boat, and the www. The stitch and glue plans I am looking at use " others use " for the hull on the same size and design for a small planing power boat. Some of the plans I have looked at are for aluminium construction. From reading Aluminium has great strength but needs lots of bracing to prevent flexing.

Sam Devlin sits in an office chair while we fasten a lapel microphone to his frayed Outback Oilskin vest. Towering evergreen trees loom overhead, creeks run this way and that, the German shepherd puppy is all teeth and exuberance.

A new barn that shelters two boats has just been completed. One is an older Devlin design and the other a project soon to be disclosed. Walk through the door and settle into an overstuffed leather lounge chair. To your right, a wood-burning stove. To your left, an array of bookcases, drafting tables, a handmade stool. At first the overstuffed chair seems incongruous: too big for this tiny space and aesthetically out of place.

When Sam Devlin talks boats, you want to get comfy, grab a hot cocoa, and stay a while. Sam has fastened name boards from past boats to the walls and to the door, with names emblazoned in gilded script or serif fonts. Scattered among the bric-a-brac are CAD printouts spread out on drafting tables or rolled up like manuscripts unfinished, tucked into corners. The schematics offer a view into the soul of the boats that Sam designs, builds, delivers, fancies, dreams, or conjures from his raw and tireless imagination.

He is always up to something. One of several buildings on site. Recently, Sam has developed an affinity and skill for building scale-model boats. Most are half-hulls and some are not even his own designs, but they all serve as reminders that his designs have been�always will be�inspired by the handsome, practical lines of work boats.

Some models were constructed for amusement, while others serve as prototypes for his full-size builds. The latest creation is among the latter, a newly designed footer called Kingfisher. Sam describes the exact moment when his interest in boats solidified. I was off watch in the galley drinking coffee while reading the first issue of WoodenBoat. I remember feeling the warmth of the oil range, the strong coffee, and the sound of the engine beating away�something about that worked for me, and I could never shake it from my mind.

A few years later Sam started designing and building boats. He became an early pioneer of the Stitch-and-Glue method of building wood boats by employing modern materials and technologies, including the use of advanced epoxy resins, fiberglass cloth, and computer-cut plywood panels. There is no one in the industry I know who cares more about the products he builds.

One could say that Sam obsesses over them, constantly evaluating and re-evaluating them from both an emotive and a functional perspective. Kingfisher, in process, is still upside down as the hull bottom is sheathed to an extra thickness compared to the rest of the hull.

After building up to the correct thickness, the boat will be primed before she is flipped right side-up for finishing. After the design is roughed out between Sam and his client, the CAD drawings are finished and all parts are ordered for delivery to his shop. Marine-grade plywood is cut at a CNC router shop that Sam knows and trusts.

Cooper, shown here, is working epoxy into the hull seams. Bulkheads are the first to be put into place. They are installed on a jig of 2x6s that sits on the floor and defines the location of each station. For the first half of her build, she is assembled upside down. Once the stations are in place, the hull is built with plywood planks that have joints designed to interlock at the kerfs like puzzle pieces: The joints themselves resemble 2-D cartoon-drawn ocean waves and, when interlocked with their mates, provide superior strength to dovetails or similar joinery.

The joints are then reinforced with glass and epoxy and installed along the outside edges of the bulkheads, which naturally taper to form the shape of the hull. Next, tabs epoxied to bulkheads form this first layer of the outer shell.

On this day, Kingfisher is getting fitted with a swim platform. Once the tabbing and joints are glassed in, the hull is ready for initial fairing in preparation for cold-molding the hull sides and bottom.

Twelve-ounce biaxial fiberglass tape is set over all the chines, and at each joint the cold-molding process continues until the total thickness is reached, bottom to top. Once planked, two layers of fiberglass cloth are laid onto the hull and separately glassed into place. The final layer before adding the stem and keel is a course of polyester Dynel cloth, also set in epoxy. Sam is meticulous about mixing the exact ratio of epoxy to cloth as well as removing any air pockets in order to ensure a perfect paint-ready surface.

Final sanding and fairing of the hull is followed by the essential step of sealing the surface before priming. An epoxy primer is applied before the boat is rolled right-side up using a custom-built jig that is strapped to the hull. Then comes the nerve-wracking process of lifting and rolling, performed by double-crane trucks, forklifts, and patience. Portrait of John Heater before sea trials of his Kingfisher Over the 26 years that they have known each other, John has commissioned everything from a foot tug, Godzilla , to Driftwood, a foot Black Crown.

Like Sam, John loves the process of designing and building boats just as much as he enjoys being on the water. After six months in the building shed, Kingfisher is well on its way to first sea trials when John expresses an unexpected desire for Sam to add a small flybridge to the sedan-style cruiser. Overnight, Sam pens a design that will work within the parameters of the boat without ruining its charm and functionality. John agrees, and in a matter of weeks, the flybridge is designed and built.

One only needs to be familiar with previous Devlin builds like the Black Crown, Blue Fin, or Sockeye to know that he is an expert in marrying aesthetic appeal and proportion to performance.

Sam Devlin and his wife on a sea trial of the Kingfisher The finished product is a craft that is as suited for slow cruising as it is for planing at 18 knots. She only weighs in at 14, pounds, so the single straight-line shaft powered by a horsepower Yanmar diesel spins enough power for top-end speeds and superb fuel burn at the low end.

Early estimates put the boat at a 4- to 5-gallons per hour fuel burn at cruising speeds. As you would expect, turns are Stitch And Glue Boat Building Videos 3d nimble and soft; one of the highlights of her plywood construction and single Yanmar is that noise underway is insignificant. The saloon and helm on Kingfisher is designed for simplicity, with a straight galley and versatile dinette seating.

Due to the size and number of windows and the painted white ceilings, the saloon and forward accommodations are bathed in natural light, essential for boating in Pacific Northwest waters. The entry is fine, and as she hits planing speed, spray strakes knock the water down just at the beginning section of the trunk cabin. Her running angle is a few degrees bow-up. Abaft the house is a cockpit perfect for a group of at least four deck chairs.

The same space might also appeal to the ice-chest-and-angler sort who desires ample room for reeling in king salmon and crab pots.

The original design actually featured a fish box in the middle of the cockpit, but it was eliminated to reduce tripping opportunities. Interior space is functional and well considered within the confines of Stitch And Glue Boat Building Videos Youtube the small but useful house.

To starboard, the straight galley sits across from a two-by-two dinette. The helm features a tidy display of engine controls and a single Simrad touchscreen. Kingfisher has a full diesel heating system installed. The forward cabin is painted brilliant white, making it light and airy. The net effect is a comfortable yet contained cruising boat with wide-ranging performance characteristics, and an interior that features utility of space, superb visibility, and plenty of natural light.

I did have substantial input, and in all cases I feel the result is pretty nice. There are few people like Sam Devlin. He is an artist and a perfectionist, a dreamer caught in the profession of boatbuilder.

But he is also highly analytical. He first gets to know each customer personally, and then figures out exactly how the customer will use each boat. Sam is constantly searching for the perfect cruising boat design: What does she look like? How long? How does she cruise? How much should she cost? When we ask him if he thinks Kingfisher is nearly there, he hems and haws, and chooses his words carefully. The Kingfisher scale model helped guide changes on the real boat, such as the bulwark height.

How am I going to cruise it? How will it make my life more fun or more enjoyable? And painting that picture�painting myself in that picture�is such a vital and important thing. He believes that if boatbuilders design for simplicity of purpose and aesthetic, more people will be drawn to the lifestyle. No one has the same needs from a boat, so Sam starts with nothing but a blank slate each time.

To see more of Sam Devlin's work and design check out Stitch And Glue Boat Building Forum Website his website! Digital Boat Show. Long-Range Cruisers. Coastal Cruisers. Brokerage Boats. Outside the Channel. Boater's University. Marine Services. Caribbean and Central America. Chesapeake Bay. Cruiser Blogs.

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