Canoe Building - Starting From Scratch
Some time around December of 2008 I actually began building my canoe. I probably have not made this clear yet, but I have never built a canoe before. Actually, I have not really built anything before that didn't come in a kit with instructions. Even with the kit, I often found myself with extra parts and a partially functioning item! Knowing my limitations going into this project, the smartest thing I could do was build a scale boat to perfect my process (which I had not even created). So I am out in the garage in the cold of winter and just looking around. I found a card table, saw, hammer, nails, and a 2x4. The first thing I did was take the 2x4 and cut a 30" long piece that would be the bottom of the boat. I proceeded to cut 45 degree angles on both sides and nailed a short section of 2x4 to the end to make the bow and stern.
After 8 more short cuts on the 2x4 and some fancy nails, I finally had the shape of the boat figured out. It wasn't pretty, but I figured I would worry about that when I made the full size version. This boat building adventure has turned out to be easy so far. Now I made two posts for the top and a platform. Once all nailed together, I flipped it over and clamped the whole thing to the top of the card table. I'm in business!
At this point I"m at a junction, I had done as much as I knew how to do. After a quick search around my garage, I came across a window with some screen in it. I decided that this would fill in the spaces between the ribs on the mold. I pulled out the staple gun and went to town. I stapeled the screen down as best as I could. I figured I would use this same methodology to build the full size canoe, so I wanted to make it as good as possible. Lots of bending the screen and scraping my fingers and I was finished with the screen. 
I try to work extra hard at being a good father. All of this time out in the garage by myself and my family starts to miss me. I have not spent a lot of time on this project yet, but it is going to start getting time consuming. So I had my son come out and help me put on the first layer of compound. I figured he couldn't mess it up at this stage. His enjoyment factor was high, and I didn't feel too bad about the project myself at this stage! From here, there were several rounds of glob on the drywall compound and wait for it to dry. This is happening in the dead of winter in an attached, but unheated garage, so the mold did not dry well or fast. I ended up having a heater on it for quite a while to speed things up. So after much sanding, I ended up with a relatively smooth form.
Before we can put the fiberglass on the canoe, we have to prepare the mold. This was a three step process, and it ended up working out very well. The goal of these steps is to prevent the material from sticking to mold. Initally this was to make the mold re-usable. Ultimately it just helps get the boat off the form in one piece. Step 1: Coat the whole mold in polyurethane. I took my time and let soak in very well.
Step 2: Melt paraffin wax and cover the whole mold. It may require re-melting to make the form even and smooth.
Step 3: Use a floor/finishing wax and re-coat the whole outside of the mold.
Like everything, we have to start at the beginning and learn. I remember my first days at school and cutting and gluing stuff together. I think everybody has used Elmer's glue before. Fitting with the tradition of a beginner, I bought Elmer's fiberglass supplies from my local hardware store. I figured it would be an inexpensive way to get used to fiberglassing. The instructions and materials where just what I needed for this job! I can honestly say that I respect seamstresses more after this project. Laying out the fabric just right across the mold is an art. It isn't as simple as just laying it down, strategic cuts have to be made in the material for it to lay down flat and take its shape. I didn't have any expreience or help for this part, so I just had to wing it. It was nice to have something smaller to practice on and not worry about messing up. It ended up pretty decent for my first try! I apologize to the reader and to myself for not having a photo of the "boat" off of the mold for this sample, but it did indeed come right off without any issues for me.
<-- Previous Reasoning for the Dream. Next --> Preparing for a bigger canoe.