Scarf & Shape Plywood

  

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Cut one end of each piece of plywood on an 8° angle. For more completed instructions see the Prepare Hull Sides page of the lake skiff section.

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Lay both ply’s scarf cut end to scarf cut end on wax paper and apply a thick coat of West System epoxy mixed with 406 Colloidal Silica. Turn one ply over and lay epoxied areas on top of each other. Be careful to align the two ply’s so that the scarfs match perfectly and the edges are straight. Put another piece of wax paper across the top of the joint.

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Carefully staple both sides of scarf joint to hold ply’s in place. Be very careful not to break the joint when turning the ply’s over to staple the other side (usually requires two to three people). Apply clamping pressure with clamps and cauls or, a jack/timber to the ceiling and a caul. Allow at least 12 hours to cure.

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After the ply’s have cured lay the scarfed ply’s across 3 or 4 sawhorses with 2x4s under them for support. Remove all the staples from both sides and sand the scarf joints. Layout cut lines with a template (see Pirogue Materials & Cut List for the template dimensions).

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The template is one half of each hull side. Starting at one end of the ply along the outside edge, lay template on the ply with the point of template on the corner of the ply. Outline the template. Flop the template over end to end aligning the flat edge with the mold line. Outline the template again. Repeat this procedure on the opposite side of the ply.

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Carefully cutout each hull side using a jig saw. DO NOT CUT THE PERPENDICULAR LINE IN THE MIDDLE OF EACH HULL SIDE! The perpendicular line is the mold line and is used to align the mold in a later step (see Pirogue Materials & Cut List for the mold dimensions). DO NOT MAKE ANY ADDITIONAL CUTS IN THE PLY, IT WILL BE USED LATER FOR THE BOTTOM OF THE HULL.

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Put cutout hull sides together and stand on end using 2x4s and clamps to hold upright and very secure. Make sure you align the sides, with the pointed ends down. Using a hand or electric planer, smooth the top edge until both sides are level and the curve of the top (which will actually be the hull bottom) looks good.

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When the top is finished, plane the forward and aft down angles until smooth and even.

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Both ends should look like this when completed. You should now have two identical hull sides.