How to Build a North Carolina Wooden Skiff
Things You'll Need
- Marine plywood, ½-inch thick
- Saw
- Power sander
- Screws
- Screwdriver
- Drill
- ¼-inch bit
- Twist ties
- Epoxy
- Wood filler
- Putty knife
- Waterproof primer
- Waterproof boat paint
- Paintbrushes
Instructions
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1
Build your widest seat. This seat will determine the curvature of the sides of the boat. Cut the top of the seat to 8 inches by 36 inches. The top of the seat is a flat piece with no beveling or angling required. Cut the vertical support pieces to 8 inches by 36 inches. Cut one edge of each support piece to 30 inches. Do this by cutting 3 inches off of each end, creating an angle. Measure 3 inches in from the end of the piece and make a mark. Start your cut at the corner of the 36-inch side and angle toward the 3-inch mark. This creates a trapezoid-shaped support piece. Glue your seat to the supports with epoxy. Place a weight on your bench (cinder blocks work nicely) until the glue dries.
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2
Build your second bench. Cut the seat so it is 8 inches by 24 inches. Make the supports 8 inches by 24 inches, then angle the ends so that one edge is 18 inches. That is, take 3 inches off each end of the bottom edge of your support, creating an angled cut up to the corners. Glue the supports to the seat.
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3
Scarf your plywood to make the sides. Scarfing is the process of putting two sheets of plywood together to make a longer sheet. You need to do this because plywood comes in 8-foot lengths and you need to make a 12-foot skiff. Lay a sheet of plywood flat. Mark a line 2 1/2 inches from the end. Use a power sander to sand this 2 1/2-inch space to a sloping, beveled finish. At the 2 1/2-inch mark, you should sand very little, increasing the pressure as you approach the end of the plywood. At the end, you should leave a thickness that is approximately that of a sheet of construction paper. Bevel a second sheet of plywood in the same manner.
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4
Glue the two pieces of beveled plywood together with epoxy. Flip one sheet of plywood over so its beveled edge lies on top of the other sheet’s beveled edge. Apply a layer of epoxy to the beveled surfaces and press the sheets together. Add weight to hold them down while the epoxy dries.
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5
Cut the sides out of the scarfed plywood piece. Each side measures 12 feet long. The aft end is 10 inches and the forward end is 17 inches. To form the slope of the front of your skiff, your sides should not be square in front. On the top edge, measure in 11 inches and make a mark. Draw an arc down to the corner. This arc can be approximate.
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6
Cut your fore and aft end pieces out of a plywood sheet The aft (rear piece) should measure 10 inches by 20 inches. On one edge of the 20-inch dimension, take 3 inches off each end to make a trapezoid shape. The forward piece should measure 6 inches by 17 inches. On one of the 6-inch edges, take off 1 ½ inches from each side, creating a trapezoid shape.
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7
Stitch together your sides and fore and aft pieces. Do this by drilling holes in the plywood along any two edges that meet. The holes should be drilled five-sixteenths of an inch from the edge of each piece, and should be one-quarter-inch in diameter. Place twist ties through the holes and tighten. This will hold the pieces together until you can glue them. Place the benches in the boat and screw the sides to them. The screws must meet the seat and supports after going through the sides of the boat.
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8
Cut your bottom piece. It measures 20 inches wide at the rear and 3 inches wide at the front. However, it must curve outward at the place where your main seat will be to a width of 36 inches. It will then curve down to the 3-inch mark. The easiest way to measure this is to place a piece of plywood under the structure you made by attaching your sides benches, and fore and aft pieces. You can trace around the shape of this structure so that your bottom piece will be the exact size you need. Drill holes and stitch this piece to your sides. You should also screw it to the seat supports.
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9
Make a mixture of epoxy and wood filler that has the consistency of peanut butter. Apply it with a putty knife to all seams. After it has dried, remove all your twist ties and fill the holes with wood filler. Apply another layer of epoxy/wood filler mixture to all seams. Cover all screw heads with wood filler.
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10
Paint the boat with a primer, followed by several layers of marine paint. This will seal the boat and make it waterproof.
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