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Minggu, 20 Maret 2016

Bahamian boats I love them

Some sketches from the past from my love of the Bahamian sailboats.

 The big boats are really amazing in the outlandishly huge sail area they carry
They can have very curvaceous hulls  

Starting some design thoughts for a commission years ago.
Work boat lines. They no longer exist 
My vision for a modern day cruiser
Carved wooden sloops that I sell to get money to go cruising on.

The Abaco Rage at anchor in Hope Town Harbor. The hull is 29 long, the boom is 45 long and the mast is 69 tall.
No you go out on the boom and put the sail cover on ! 

Sailing with my Ex wife Lawnada I our 13 Bahama Catboat that I had built. We are setting out lobster habitats to get lobsters to supplement our food costs. We ate lots of Lobster when we lived in the Florida keys.  

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Rabu, 16 Maret 2016

I started the galley cabinets

Now that the window frames are ready for windows, the next big wood working project is the galley cabinets. I have quite a few more cabinets to build on board, but the galley is the heart of the salon and a good place to start.
 

 

 

 

The galley layout is basically a "U" shape. On the bulkhead wall that separates the raised pilot house from the salon is where the refrigerator will reside next to the engine room exhaust/intake chimney. Above the refrigerator is a 30" wall cabinet that will house a microwave oven. Next to the microwave oven will be a 36" double door wall cabinet with shelves. Below the 36" wall cabinet is a 15" base cabinet with a drawer and door. On the port wall of the layout is where the LP range will reside. I built a cabinet for the range to sit upon, and also notched out the back of the cabinet so my 6" air conditioning duct for the wheel house can sneak past. I was also able to get two small shelves in the range cabinet that will have a  single door front over. Because of needing space to get the fridge in and out of the galley, I  had to build two 7" fillers along each side of the range. Along with the range and the two 7" filler pieces, the width of the galley from the fridge to the other cabinets is 32".  Im going to build two drawers on their side in those fillers ( 4" drawers) for a spice rack on one side and hanging utensils on the other. Ill get in to more detail once I start finishing the cabinets. Continuing around the "U", is where the sink base will reside. I built a 36" sink base to accommodate a home size double bowl sink. It was important to us to have a large sink and its a detail all will appreciate. Next to the sink base is an 18" base cabinet with three large drawers.


 

 

 
All the cabinets and wood work on board the boat is American Black Cherry. Trees for the lumber were cut off of my property, and milled by neighbor Carl Claypool and his dog peckerwood.

My method of building the galley cabinets are to build a box, attach a face frame, then build style and rail raised panel doors. On other parts of the boat, I saved time,  money, and space by making some of the cabinets "built in" which  utilizes part of the hull as the cabinet "box". Because the wheel house and salon are still sitting in my barn, building cabinets as boxes is the only practical method.

Each box is built from 3/4" birch plywood. There is only one place where the side of any cabinet will be visible, and that side was made with 3/4" cherry plywood. The backs of the all the cabinets are 1/4 plywood, and I added a 3/4" rail to the top of the base units back, and to the top and bottom of the wall units back. The extra rail is to give me something more substantial than 1/4" material for mounting the units. The tops and bottoms of any cabinet is also 3/4" plywood let into a dado in the sides. The wall units have a top and a bottom, the base units only have a bottom as the counter will make the top.  I rabbeted the sides to accept the 1/4" back.

The face frames are solid cherry and have a width of 2". All the face frames were built using the Kreg pocket screw gizmo. I cant say enough good things about this method of building face frames, and its become my number one choice when applicable.

The doors are the style and rail method and because I want a nice looking job, I decided to use a raised panel. I went with a traditional raised panel which is a 15 degree angle. I have an ogee cutter for my shaper, but I wanted something more in tune with what one would find on an older boat, and the 15 degree raised panel suited my thought. I cut the style, rails, and raised panels on my old Delta shaper.  Ive posted about the shaper before, and Ill again say that caution is for sure the preferred attitude to have when using this tool. When the panel raising bit that weighs about a pound  is spinning at 10,000 rpm, and you need  hearing protection from the noise it make, a serious amount of respect quickly builds. When raising the panels, I use the table saw and remove a lot of the waste before starting with the shaper. I take light cuts, and always do the end grain first. The end grain is the hardest material to cut, and in case I have some chipping or a minor blow out, the next cut going with the grain will usually fix any end grain issues. The cutter is carbide, and sharpened to 600 grit so its nice and sharp. The shaper has a great device to raise and lower the bit, and along with the micro adjustments on the fence, the level of precision is fantastic. When finished with shaping the panel, I sand it to 220, and give it a light coat of Cherry stain. Having some color on the panel before assembly will help prevent seeing a line at the style and rail joint once the panel starts moving with seasonal humidity and the wood naturally darkens.  I expect the Cherry wood to darken five or ten shades once it starts seeing some sun. The natural darkening is one reason I like Cherry.

Ive been mocking up some of the structure in the salon. For the galley, I mocked up the bulkhead wall, and the engine room chimney. I also mocked up the ceiling above the fridge. The finished ceiling is going to be a bead board which is 5/8" thick. Using 1/4" plywood for the ceiling is not ideal and makes it hard to get a good scribe joint against the face frame. I left an inch of material to scribe for final fit against the real ceiling.  Im being pretty accurate, but Im also giving myself lots of wiggle room in regard to extending face frames past the cabinet boxes in critical areas for plenty of room to scribe and fit to the finished wall and ceiling material once those are installed.  Mocking up is not something Ive done in the past, but Its the only way I can do this job. Ive found a few issues during the mock up and was able to easily change some things that would have been a pain to do later down the road.

I could have purchased a set of rub collars for the shaper and made the raised panels fit the curve of the ceiling. Im going to deal with the curved ceiling regarding the door fit by making the top rail of the doors fit the ceiling curve. Ill make the upper rail four inches vs my standard two inches and scribe it to fit the ceiling. The other option is to leave the door square and live with the stepped look of the square door against the camber of the ceiling. The different thickness of the curved top rail vs the square lower rail might make it look odd, but I think the overall look will be ok. Well see how it looks in about a week.  The three doors you see in the picture above are two for the sink base, and one for the 15" base cabinet next to the fridge.

There is much more to post about the cabinet build, and as I get further along Ill add more detail.

Cheers
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Kamis, 04 Februari 2016

I started the super structure interior

Because I am swamped with paying work, Ive taken a few days off of the build. Hurricane Sandy has changed that, and caused  major slow down in my work, so Im back to the important things in life... the boat build. I have to say that while we are four or five hundred miles from Sandy, we had 25 mile per hour winds sustained last night while  she came ashore.

To begin the interior, bolting lumber to the metal frames is the first order of work. To make it seem like I was getting something done, the first attachment I made was to bolt lumber to the ceiling frames. Because of the camber of the ceiling frames and not wanting to piece things together, I had to use a 2x6 for the ceilings. It seems like a lot of waste, but all the off fall was ripped again for the side wall frames.

The barn is about as full as it can get and the only place to set up my table saw is under the roof of the aft deck. I had to position the saw so I can make long rips through the door of the salon.

The basic method of getting the ceiling beams done was to clamp the 2x6 to each end of the frame. I then used a scribe set for the gap between the 2x6 and the frame at the center of the frame and scribed the top ( roof  ) side of the cut. Because the frames are so long, and the curve not that radical, I was able to use a circular saw to cut shy of the line. The cut put the saw in a bit of a bind, but it was not too hatefull, and thats what tools are for. Once the roof side was cut to shape, I re clamped the board to the frame, set the scribe for 5/16", and scribed the interior side of the cut. Once again, I used the circular saw ( vs the band saw ) and made the cut. All the boards are being held proud of the steel frame about 5/16" so foam remains on the frame flange after the foam is trimmed. With the board now cut to fit, I applied a bead of polyurethane adhesive and re clamped the board. I then use my right angle air drill, and drill through the existing holes in the steel frames. Next I use a hammer to drive the 1/4"x2" carriage bolts home, followed by a flat washer and a nylock nut, then tighten all the bolts using a 3/8" air ratchet

Gluing the lumber to the frames in addition to bolting might seem like over kill, but bolts have a funny way of working loose in lumber, and since the adhesive is not that expensive, I think it to be good insurance to prevent a squeak.

As I type this post on this rainy Tuesday, I have all the ceiling beams finished in the wheel house, salon, and aft deck. I also have the wheel house walls and windows complete, and am getting ready to start on the salon. Another full day, and I should be finished bolting all the lumber in place.

I have an insulator  showing up in the morning to give me a price on foaming the interior. Im going to foam the interior down to within a couple of inches of the weld zones.

While I still have the boat in the shop, Im going to also install the Cherry plywood at the window opening so I dont have to deal with that at the cold boat yard. Im  using a clamp ring for the window installation, so I have to have the finished wood in place in order to install the windows. The window installation is also complicated by the fact that  the maximum wall thickness at the window is 2 1/4", while the frame thickness of the boat is 3 7/8". Its kind of a strange deal to describe, but on the salon windows and the side windows of the wheel house, the windows will be set in by the difference. The front wheel house windows will be flush with the  interior as I was able to make the tabs work out to 2 1/4" wall thickness.  It will look OK as Im going to spend a righteous amount of time getting the trim right, but it does add a whole bunch of work to the window trim job. Im not quite sure how the finish window trim will look, but Im going to use each clamp ring as a template before I install and make a pattern out of paper board for future fabrication of wooden trims for the windows.

The weather had for sure turned  here, but I have plenty to keep me busy getting the super structure in a more finished state. Taking the super structure as far as installing the windows before shes landed and welded in place has entered my mind, but I think it too risky. I can install lots of the trim, some of the ceilings along with some wiring and a host of other items before I have to commit to taking her out of the barn. While Im aching to have her assembled at the boat yard, all of this work goes much faster while shes in the barn.


Cheers 
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Rabu, 27 Januari 2016

LAnse aux Epines House a house I built in Grenada

The truth is I did the drawings, engineering, supervised all the construction, taught the locals new building methods and with the owners ready cash flow built this place in local record time.
Iam sharing the tale of this project here as a record for my kids to look back on to show what can be done with a basic education, ( Iam self taught from 9th grade on) common sense, hard work and a bit of money.

In my life time I have found all my jobs by face to face meetings. Most by chance, some by referrals from past jobs. Living on a sailboat and sailing to distant islands being on the move all the time gives me the ability to come across lots of different opportunities with my basic skills. As stated, I do not have a high school diploma, but I feel good common sense has been a good traight of mine. I can read so Iam always educating myself. The math I know is high school level. Iam good a geometry, accounting, and understanding that there are no short cuts with math.
My math skills have held me well in dealing with other peoples money. I think of their money as mine so keep meticulous records. Since I have worked my way up from the bottom I know how to make a dollar stretch a long ways. 

I was taught by my Cuban grandfather that had immigrated to New York in the middle of the depression speaking no English this simple rule." Cristobal, you dont need to remember everything, you just need to know where the information is and how to use it." He found a job, raised his young sons, and going to night school received a Masters degree in engineering. An American success story.
I have added to this advice that I never lie if I dont know how to do something, but in my head if I know where the information is for this new project I will get back to you soon with info.

I had many years before worked for six months for a friend in the Florida keys building concrete houses. My job consisted of building plywood forms, laying in the steel work, pouring cement, stripping off the forms, and starting the whole process over. During this time period I helped build 6 buildings. I learned a lot  about this building process during this time that I would carry over to this job.

This job came about by chance. I was hoisting my dinghy on deck in Prickely Bay in Grenada getting ready to sail north back home to the Bahamas. We were low on cruising funds. We had just crossed the Atlantic a month before from the Cape Verdes after a years sailing around the Atlantic islands. It was time to find a good job and to get our young girls into school again. They were doing Calvert home schooling but our oldest wanted to be part of the mainstream. She was 15 and wanted what all kids that age wanted, a life of her own.

Before the dinghy was stowed our friends Tim and Galye Evans yelled over from a big sloop that had anchored between us. The owner of the sloop wanted to talk to us about a job he had in mind.
I put he dinghy back in the water.
Hurricane Ivan had just destroyed about 50% of the houses in Grenada including his which we were anchored to the leeward of. It had been an old small bungalow that had originally not been built well to start with. It was a wreck. He wanted to build a new stronger and bigger place.
He did not want to deal with the locals at their pace and the way they would deal with costs and building standards. He wanted a hurricane proof new place, a huge pool, a replica sugar mill apartment 
With its own pool and the new place would have a gym, and on and on.

When telling this to Tim and Gayle on his boat as they were visiting, Tim pointed over to the Hogfish and said, " Chris is the man youre looking for". He came over and we talked. I looked at his sketches of his vision. We argued about building standards. He wanted to save a bunch of the destroyed house. I explained my vision to do what he was looking for. After a couple of hours of back and forth he held out his hand and said he wanted me to build his house. We shook hands and struck a deal.

We really enjoyed our time In Grenada. This job took 1-1/2 years to do. Our oldest daughter Kalessin stayed for the first year going to school ashore with her sister. She then at 16 moved to Florida and went to high school there staying with a friend. We would catch up with her when this job was over.

After hurricane Ivan the place was pretty much bare. We rebuilt the dock first. 3 large Catana catamarans had flipped over three times crossing the bay to land on the original dock destroying it. Don Streets little "Iolair" ended its life there too. I have its bronze Wickham roller furler that I dove up hanging at my house. The winds had been so strong that the red clay tiles a mile across the windward valley were piled up against this house. Asphalt shingles were stuck 4" into the trees that were still standing like Ninga blades.
These are the sketches that the owner provided me with to start on the designing of the house.
He explained verbally what he wanted.
This is his land scaping vision.
I supervised all the trench digging with this JBC using my Plastimo hand bearing compass to get all my tangents. The 21 year old driver was from Guyana and had to dig all the trenches and move the dirt up the hill to be saved for use under the pool. He was fantastic moving this thing around like a one armed crab. The trenches took 2 weeks to dig.
The crew starting on the foundations. Because I had free run on how to design and build this place I just made sure everything was at the Dade County Code level or above. I put steel through every block and pored all the walls solid.
We had lumber stored every where as there was not much space on the top of the hill where the house sits. We were always moving stuff.
The bottom of the pools infinity edge.
The Sugar Mill started. Thats Paul. He had chopped his brothers hand off a month before in an argument with a machete. He was a very quiet worker. 98% of the guys had zero body fat. Very fit and could work all day in the heat and sun. Iam used to it to but at times the sun over head was strong at 12 degrees latitude.
Sugar Mills first floor. This building has been rented non stop since it was built.
This house design called for some very long open spans inside. 22 for some. I just engineered these huge box beams in plywood and using glue. All wood here is Green Heart from Guyana. When orderd at 2x12" thats the way it came. Very heavy. I ordered $189,000.00 US dollars worth with all dimensions listed. The order came in five 40 container boxes with all the planks Jammed in without any order. All had to be removed in one day, stacked and stickered to length. What a day that was, just brutal as this wood weighs a ton each. Three men to pick up one plank.
When all was done I had been shorted about $32,000.00 in wood. I faxed back what they had not sent but I had paid for. Amazingly the rest came on the next freight boat without a word. So much goes on here like this I beliveve they do this hopeing the rich foriener does not notice.
Looking down at the pool. It rains every day so stuff just grew all the time.
I design my floors to never move when walking on.
Second floor walls were 10 high inside.
The steel guy worked 10 hours a day with a helper to keep up with the project.
Victor a mason in the front porch
Pumping cement was always a challange as the pipes would always clog with a conch or some rock. 
The pool bottom about ready to be filled in. The pool is the largest one in Grenada. Its ten feet deep.
Contains 135,000 gallons of water. I put in French drains all over the place. When filling in I compacted the dirt and watered it down for days to be as compact as possible. The floor of the pool took 112 yards of cement. This pour took 22 hours to do using all the local cement companys. I had floodlights, a food cart and changed the crew out on watches to get this all done with a wet edge. Its bottom and walls were 14" thick with Double rebar matting. No cracks in the entire project to date.
Pool bottom
Dining area going together.
Upstairs rooms. Walls were sheeted in Hardie board planking
Always storing wood some where.
The owner wanted to build the second story on top of the old house. I said no as it was too weak.
When he left to fly back to Europe I dug out and built proper foundations, collums and support perimeter belts. So he had a new foundation inside the old one. He did not notice this till after the whole project was finished.
My main wood worker Etteane and me on Friday party day seeing who could stick their belly out the farthest. Etteane is from Dominica. He is a fantastic craftsman. I believe he was stoned smoking pot every day he worked for me. Most guys smoked pot all the time. We never had an accident during the entire build. But I had to keep pulling the pot plants that were growing from the seeds that were falling out of their joints. 
Mr Rolle and I this trip catching up on old times. He is a master carpenter from Dominca. Does not drink or smoke. He worked building the house with his girl friend doing all the detail work, like all the stairs and scarf joints. Here we are this year with me hiring him to rip and cut rough teak for my current project redoing a teak deck on Wild Bird in Antigua. I sailed to Grenada to buy the teak and get Mr. Rolle to help me make up all the planking as he is as fussy as I am about details and he has all the big tools needed to do the job. When we were building this house I was flying back and forth to Miami to buy supplies. I could bring in everything without duty. Duty is so high there that most workers could not afford tools. I bought Mr. Rolle a table saw, joiner, thickness planer, chop saw and other hand tools. These are the tools we used to shape up the rough teak. All being used everyday but in like new condition. Its no big deal to sail 700 miles to get supplies and stuff done right.
LAnse aux Epines house today.
I love this pool but with the trade winds blowing over it it loses 1/2" of water a day through evaporation.
The front drive way
Today with the owners latest boat.
Rachel a few months ago enjoying the morning where Victor the mason was a few years ago
Kitchen
Dining room
Stairs going up to the five bedrooms. All wood is green heart and is all bunged.
Living room being cleaned by the house keeper. See all the collums I put in while the owner was gone to support the second story better. 

All the beams are open and all finished bright
Owner wanted this bathroom set up. Floors are oak. Walls cypress.
8,500 feet of Italian marble throughout
Pool pump room.
Starting the hill climb looking up at the Sugar Mill
Marvin the grounds man. He worked for me as a general helper. When the house was finished I recommended him to stay on as the maintence man as he was 19 at the time and I could see that he was very bright and hard working. Hes been there now 11 years. You can just see the Hogfish off to his right.
A dormer I installed five years ago on a trip down island to race and work. These let the heat out in the evenings. The house is very cool but the owners tend to lock all the doors at night as they worry about crime. The air cant flow so it gets hot. I like living on a sailboat as I have a moat around me at all times.
The porches are 7 wide
Cabana. Lots of slippery Italian marble tile about.
Sunset
With so much rain in Grenada its easy to landscape.

In the pools infinity edge I put a 4" ledge down 4 for your toes to hang onto. Its 10 deep here as the owner who is just to my right wanted to say he could float his 60 sloop in this pool.
Iam at the left in this picture. The mast you see comimg up in the middle of us is his 60 sloop. The mast is 85 tall.

During the build of this place I had at times men from Montserrat, Antigua, Dominica, Guyana, Cuba, Nevis, and many Grenadians all speaking their version of English. The deal I made to all my men was that if they stuck with the job till the end they would receive a 10% bonus in the amount of their wages for the project. They wanted to work 10 hours a day 7 days a week. They were used to the local way of the boss showing up in the morning for a bit and then disappearing the rest of the day. That left lots of time for slacking off.

They had never had a boss like me though. The house site was a two mile walk for them to get to in and out of after a 1-2 hour local bus ride from the other side of the island.The local contractors let their men find their way to the work sites.

I picked up everyone at the two mile bus drop off site and drove them all back and forth each morning and evening starting at 6:30 in the morning and ending at 6:00. So they saw me first and last. I explained to them that in order to get 10 hours of pay they had to work 10 hours but at a nice even pace. All the work I delegated everyday to each crew I knew from my own experience what and how long it would take. So I never asked more than what could really be done. This they picked up on real fast. I also explained and showed them many new ways to build things that were much faster than what they had been doing. This they liked as they learned stuff that they could apply to their own houses. Most West Indians want to work but will try and drag out a job with the idea that it will last longer if it takes longer. This system I had to change. I did it by example of showing them how to nail up a stud wall 55 long in one day as opposed to the week and a half they would have taken. I hired everyone that asked for a job explaining that they had 3 days to prove their worth. I also gave everyone a raise after the first week if they could do what they claimed. When they got better more raises. If they were seen slacking off I fired them. In no time at all I was seen as being fair and hard working. I got a good crew of 20 guys moving along enjoying seeing this house going together so fast and built like no other in strength and details. The other local builders saw this too. I started to get offers to build more houses. 
At any time I would have my core crew of about 30 men working with at times another 15-20 subcontractors doing electric, plumbing , rock work , etc with me having to oversee all they were doing to stick to my standards. 
There was every shade of black, brown, redish brown, chocolate and tan working. To these guys if you were the blackest black and were a Rastafarian from Jamacia or Dominica you were the coolest guy. Then it was all about shades of black and brown. So when saying to me to " Go don a speak dat dark skinned mon"
What ? They are all dark skinned. Not really when you look about. Lots of shades going on. They said I was a red skinned man between us but when an official came to see the boss they always said," He da White guy over der" pointing at me.

West Indians do not want to work alone so will always pair up with a friend so they can talk. They talk continually. Most all do not want to be put in charge at all even for more pay. So you have to get them sorted out into working groups and give them a doable goal with the alpha guy telling the other guys that they were not doing it right or to hurry up. They became leaders with out knowing or asking. Then you can leave them to it and go on to the next group and project. This has worked well for me in building boats too. 

At times during a pour with 8 guys yelling at each other in their own local version of English with most of them not understanding each other I would step in and yell " Please speak the Queens English!" 
They all in their youth went to British schools so can speak clear English if they want. But its not so cool so most just go on with their local version of talking like a Jamaican. " Ah boss, de Conch be stuck in de hose, wa to do?"

It was a daily challange to keep things moving along at a good steady pace. Most foreigners that get to the island that are used to first world order look at everything down here as chaos. I look and see a way to try and steer and control this chaos. To survive you have to be able to punt, kick and weave every day like its a soccer game. No day will be alike or unfold as you planned and hoped for the day before. It will pour rain for two hours, then be hot as hell with no wind, the pump you need for the days pour is broken, the crane you can hire has no dump bucket but his rival company does, so how to make it all happen. 

Knowing the local mind set and customs helps. You have to greet everyone with a good morning or good afternoon before going on about business. You have to find out where all your main suppliers hang out so when they are supposed to show up you instead track them down and make sure they know you want them and get them to come to the job site. They want the job but most are in no hurry to do the work. Paying your bills right after the job is done does wonders. Now they know you mean business. Dont ever give money in advance. You buy the materials on your own and when so much is done then you pay. The going pay rate for the top carpenters was $ 45.00 a day, $30.00 for masons and $25.00 for laborers. It has not gone up much since then. 

Looking back I still cannot belive that I was offered this job with only Tim and Gayles reference after only a few minutes conversation. Such is boating life. The owner is a very successful Irishman that was very frugal with his money. In the end I built the place at a cost fully furnished for $138.00 US a square ft. I got everything in duty free because the Chinnese were building a new Cricket stadium for the Grenadians for the up coming world Cricket match to be played there. The island needed hotel rooms. I counted up 11 bedrooms and bathrooms so that it fell into the hotel act and enabled me to save about $400,000 in duty. They never came out to count up the rooms or inspect the building for code. The third world has lots of loop holes you can wiggle through.

When rachel and I sailed into Prickely bay this winter the owner had just left to go to his other houses in St. Barts. He graciously offered the place to us to use while we were there. Tim and Gayle were sailing back there after ten years absence in their new Boat Wild Bird. They had not seen the place since I started the project.
Along with them and other new friends we had some great parties around the pool looking out over the bay and our sailboats at anchor below over the next few days. 

This project has been one of many that I have taken on or been a part of in our sailing travels about the Atlantic basin. I have never been lacking for a job or work while sailing. Thats why I carry so many tools with me and need a vessel that can carry this load. You to can do the same thing if you have basic work skills, energy and good common sense.
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