Thursday, September 15, 2011

Decks and Bulkheads: Assembly and Installation

Decks and bulkheads are used at each end of the canoe to make up a flotation chamber in the stern and a flotation/storage chamber in the bow.

The cedar strips are glued and clamped together to make an oversized blank that is later cut to size. Many more clamps were used than are shown in this photo.


A nautical compass rose made up of various hardwoods is added to the bow deck before the cedar blanks are sanded smooth and before fiberglassing both the front and back sides. Multiple coats of epoxy are applied to the fronts so that they can be sanded smooth without exposing the fiberglass.



The bulkheads are fitted and then attached to the hull using epoxy/wood-flour fillets. This photo shows a bulkhead being installed. Masking tape is used to control the size of the fillet and minimize the cleanup. Note, that a mahogany steam-bent deck support has been added along with a deck support beam.


The decks are epoxied in place. It takes quite a few clamps to get the deck to conform to the upward curve of the bow and stem.


This photo shows, from the underside, how the deck is left proud of the curved support beam while being epoxied. Once the epoxy has cured, the curved edge of the deck will be cut flush by using a router with a flush trim bit.


Here is the finished product: