Transcript
ABrockway
Skiff
Howto
Build
By Timothy C. ViselText By Alex Disla
Layout by Alicia Cook
The Sound SchoolRegional Vocational Aquaculture Center
New Haven, Connecticut
The Sound School Short Course
IndustryWorkshop Series
Connecticut Regional Vocational Agriculture System Public High Schools of Choice Since 1955
Updatd July 2008 by Faiza Riaz, Sound School Communications Office
PrefacePreface SixyearsafterMr.Richard“Earle”Brockwaypassedaway,thepopularityandinterestinhisdesigncontinuestogrow.LocaltotheOldSaybrookarea,thedesignconceptisbeingcarriedoncommerciallybyPerssonBoatBuilderswhobuildsasimilarseries.TheRiverSchool,andlaterMaritimeEducationalNetworkconductedlecturesonBrockwayBoatsinOldSaybrookjustacoupleofmilesfromEarle’sboatyard.Brockway-styleskiffsarealsobeingbuildinseverallocationsinMassachusetts,mostlyonCapeCod. HereatTheSoundSchool,wesponsorworkshopsforout-of-schoolyouthandadultsinterestedinboatbuildingattheMaritimeEducationNetwork.TheskiffusedintheworkshopseriesistheBrockwaydesign.Duringlastyears’program,severalworkshopparticipantsaskedaboutothersizes(9,12,14)tobeaddedtothe16.Although,Ihadownedallfoursizeskiffs(therewasalsoan18andarare20skiff),Ihadplansonlyforthe9-footdingyand16-footextrawideskiff.Duringthefallof2000,IwasaskediftheboatbuildingprojectcouldbeexpandedtoincludesmallerskiffssuitableforBoyScoutprojects,SundaySchoolprojects,andtechnologyclassesatareahighschools.Inthefollowingpagesthe14-footskiffisintroduced.The14-footskiffismoresuitedfortheaboveuses. Several“Brockways”wereconstructedbyattendeesoflastyears’workshop,taughtbyNedCostelloofTheSoundSchool,andtheirvesselshelpskeeptheBrockwayskiffsalive.Theotherplansincludedinthisaddendumfollowthesamebasicconstructionproceduresasthe16-footguideusedbyMr.Costelloin2001andlaterbyMr.BryanAmantaofDanielHandHighSchoolin2002.
Good Luck with the workshop series!TimothyC.Visel-Coordinator
AnaddendumtoPlywoodWorkBoatsforSmallScaleFisheriesURIKingstonRhodeIslandFirstprintingUniversityofRhodeIsland1981I.C.M.R.D.CollegeofResourceDevelopmentReprintedMaritimeEducationNetwork2001RewrittenbyTimothyC.Visel,TextbyAlexDislaandDiagramsbyAliciaLynchforTheSoundSchoolIndustryWorkshopSeriesNovember2001.
September2002-HowtoBuilda14-FootBrockwaySkiffConstructionGuide
ReprintsoftheBrockway16-footskiffconstructionguidecanbeobtainedfrom
MaritimeEducationNetwork,203FerryRoad,OldSaybrook,CT06475
orTheSoundSchool-AliciaCook,VocationalAgricultureCommunications.
TheSoundSchoolRegionalVocationalAquacultureCenter,60SouthWaterStreet,NewHaven,CT06519
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IntroductionIntroduction The14-footskiffdescribedhereisbuiltfromconstruction-gradestructurallumber,plywood,framingandtrim.EarleBrockwaymaximizeddesigntosavematerials-“nowoodisscrape”heusedtotellme-andstrivedthatonly“wooddust”wasleftafterbuildingoneofhisboats.
IhaveownedseveralBrockways,a9-footdingy(myfirst),two12-footskiffsandfour16-footskiffs.Ihadoneandhadriddeninseveral14-footskiffsbuttheywerealittletoosmallforanoysterbusinessandcommercialfishingwithmybrotherRaymond.Isoldthe14-footskiffonlyafterafewweeks.Thirtyyearslater,Iwaslookingforamodestsizefamilyboatand,afterlookingataluminumandfiberglassboats,Icametorealizethata14-footBrockwaywasnowtheperfectfit.Unfortunately,mylongtimefriendRichardEarleBrockwaypassedawayin1996.Thesourceof“Brockways”wasgoneandsoonIthoughtthelegendoftheBrockwayskiffswouldalsobegonefromtheConnecticutcoast.Thenafortunateeventoccurred.Iwasaskedtocontributetoalocalshadexhibit.Theplansforthis14-footBrockwayweretakenfromaskiffthatwaspartofashadfishingexhibitattheDeepRiverHistoricalSocietyfromJulytoAugust2001.Ihadbeenlookingforanold14-footskifftocopyandthiswasit.IwanttothankJeffHostetlerandEdithDeforestoftheDeepRiverHistoricalSocietyforprovidingtheopportunitytotaketheplans.EveryyearitseemsthenumberofBrockwaysgrowslessandless.Strong,sturdyandveryfunctional,theplywood(AC)heldthelifespantoabout10to15years.20yearswasoutstanding-afewevenmadeitto25.Timeastheysayisoftheessence,butinthema-rineenvironment,plywoodhasalimitedlife-span.Fortheoriginalpurpose,asstrong,durable,andlowcostworkboats,Ibelievetherewasnonebetter.IguessthatiswhytheinterestintheBrockwaydesignhasnotfaded,butinfactisgrowing.ConsideringthenumberofBrockwaysconstructed(itisinthethousands),asavesseltype,itisbecomingthemostwidespreadwoodfishingvesselinrecenthistory.SomefeelbecauseofitsintroductionoverseasbyPeaceCorpsvolunteersinthemid1980’s,theconstructionstylemaysurpassthosedesignsspreadthroughouttheworldduringthelasttwocenturies.
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The 1�-foot SkiffThe 1�-foot SkiffThe Brockway 14
Coast Guard Capacity InformationHull Number None - Built about 1975
Maximum H.P 15Maximum Persons Lbs 500 Lbs
Maximum weight persons motor and gear 620 lbsBuilder Brockway Boatworks - Old Saybrook, CT (last constructed 1996)
TheoriginalBrockwaydesignhasbeenmodifiedovertheyears.ThefirstBrockwayswereallplankedvessels,butbytheearly1950’s,plywoodsideswereusedwithaplankedbot-tom.Afewyearslater,allplywoodmodelswereproduced.
In1976,theUS.CoastGuardaskedMr.Brockwaytoincludesealedfloatationonallskiffslargerthan12feet.TheyprovideanextramarginofsafetyastheBrockwayskiffswereoftenoverpoweredandoverloaded.Althoughthe14’CoastGuardcapacityplatelistsatotalof620pounds,Isawseveral14-footerscarry15bushelsofoysters(aboutone-halfton)plustwopeopleduringtheearly1980’s.Mostoftenthespaceundertherearseatwasenclosedtoholdafoamfloatationorsolidstyrofoamblock-Earlehaddesignedtheseatheightssothe6gallonmetaltanksprevalentduringthistimecouldfitunderneath.AsthefoamcompartmentsalteredtheseatdesignEarleinstalledframesinsteadoftheusualmiddleseat.Myfeelingswerethedesignchangeswerewarrantedfortheextrasafetyandusedbothtypes.Thelargerskiffshadabowcompartmenttoholdtheexpandedfoam.Othershadspecialized“sideseats”incorporatedintoaframe.Afterthisperiod,manycommercialfishermanpurchasedtheseskiffsandtorethefloatationcompartmentsout.Ibelievethefloatationprovidesanextramarginofsafety.Somecommercialfishingapplicationsdictatedthathaulingbedoneattherailsoyouhadthisconflictbetweensafetyandfunction.
Havingswampedthe16-footskiffseveraltimes,theydidn’tsink.Ineverusedanythingovera25Hpengine.Severalincidentsofputtingover100hponaflatbottom16-footskiffpromptedtheCoastGuardregulationsoncapacity.Itwasspeedthatmadethesevesselsunsafeandthe“pounding”tendedtoloosenthejointscreatingleaks!Theywereneverdesignedtobespeedboats.
Theseplansaredesignedtobeusedwithapreviousguideonhowtobuilda16-foot“extra-wide”Brockway.Thereforeseveraldesignfeaturesarenotdescribedinthisplan.Tocompletelyunderstandthedesign,the16-footconstructionguideshouldbeconsulted.
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13’9”
Diagram 1
BowStem
SternTransom
BottomEdge
31”
2”
Diagram 2BottomEdge
15.5”
TopEdge
Construction GuideConstruction GuideThesidesarebuiltfromtwo4x8sheetsof1/2-inchplywood.ACplywoodwhencutproducedaskiffmeasures14’1.5”atthetopedgeand12’7”atthebottomedge.
FromTransomtoStemtheskiffis13’9”inchesoverall.
Plywoodsidetopmeasures14’1.5(true)Plywoodsideboatmeasures12’7”(true)
A=Sheetextends3.5”beyondperpendicularlinetotransomB=Sheetextends15”beyondperpendicularlinetostem.
Stemdetails-Stemis33”longextends2”abovesidescuttofinallengthaftersidesonstartwith40”piececutsameasdetailsfor16-footskiff.
Square4x4 Shapetoacceptsides
13/4”13/8”
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JointSheet(1) Sheet(2)
Sidelookslikethisfromtwo8-footsheets
73.5”96”
70” 81”Atjoint19.25”
3.5”
3.5”
15”
15”
BA
“A”measure3.5inchesinfromBottomcuttoedgeoftopsheet“B”measure15”inchesinfromBottomcutouttolongeredgeoftopsheet
AB
FinalSidemeasures14’1.5”and12’7”Bottom
A+BSectionscutfromsideSidelookslikethisifcutfrom16-footplywood
Cutsidestomakeshape.
1)At3.5inontopsheetmarkeddown 15.5”fromTopEdge 2)At2’3.5 16.5”fromTopEdge 3)At4’3.5 18.5”fromTopEdge 4)At6’3.5 19.5”fromTopEdge 5)At8’3.5 20.5”fromTopEdge 6)At10’3.5 22.5”fromTopEdge 7)At12’3.5 23.5”fromTopEdge 8)At12’10.5” 24”fromTopEdge
Thencut15”outanddrawto12’10’.5markormeasure15.5downatstation1andmark24”downstation8usechalkline.Thisshouldbeacheckasthelineshouldbestraight.Earlehatedtowastewoodsothecuttingplanmusthavecomplementedanotherboatdesign,perhapsa9-footdingy.Theplanshadscrapbutnodoubtwasutilizedelsewhere.ThesidesheusedwasrarelybuiltfromonesheetalthoughIdidhavea16-footBrockwayskiffbuiltfrom16’continuoussheetofmahoganyplywood.Mostoften,Mr.Brockwaywouldbutttwoplywoodsheetstogetherwithaplywoodsplice.Thesplicewasplacedatthemaximumwidthasthespliceactedtoflat-tenouttheside.Earlewouldplacethemiddleseatjustbeforethesplicelateraframewouldbeplacedhere.IwatchedEarleplaceapieceofwoodonthesidesandjumpupanddownonituntiltheskiffreachesthepropershape.Thisiseasiersaidthendone.Ofcourse,ifyouuseorobtain16’panels,allthisisnotnecessary.TheBrockwayboatwascharacteristicallyconstructedfromcommonconstructionlumber,thusthe4x8plywoodpanels.
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HowToCutSideslaytosheetsonflatsurface4x8sheetsACplywood(nolargedefects)
73.5” 96”
70” 81”DiagramSidesshowing“joint”orbuttblockbetweensheets
8’8’
4’
Thiscreatesa16’x8’Panelfromwhichtwosidesarecut(measuredepthsfromtopstraightedge)
Sheet(1) Sheet(2)
3.5”
3.5”
15”
15”
2’3.5” 4’3.5” 6’3.5” 8’3.5” 10’3.5” 12’3.5”
1 2 3 4 5 6 7 8 9Stations1to8
Station8is12’10.5”,9is14’1.5”
Thesidescanbecutbysettingoffstations(lofting)buttheBrockwaysusedstraightedgessosidescouldbemoreeasily.Stationmeasurementcanhelpindeterminingboatplans.Belowisthestepstoquicklycutoutsides.
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Sheet #1
Sheet #2
A=3.5”B=73.5”C=70”D=15.5”E=51.5”(E1toE2)F=18.5”Deep
How to Cut Out Sides
LayoutofBothPlywoodPanelsshowingcuttingplans,locationofallscrap(waste)ofsheets1&2.The14’Brockwayskiffdoesnotfullyutilizetheentirelength,sowhenthetwopanelsareflat,cutapiece22.5”x48”off.Thiswillleavearectangularpiecetouseelsewhere.
22.5” 73.5” 96”
48”
Starthereforthefirstcut73.5” 96”
96”15”
81”
24”
15”
E1 E2B
D
A C
F
G
73.5”22.5”G=Atbuttblockjoint
measure≈19.25”Deep
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Twopeople-onemeasuringandmarking,onecheckingandcuttingshouldbeabletocutsidesoutin15minutes.
Placetwosheetsof1/2inchplywoodendtoendtoform4x16panel.
1)Takeametalstraightedgeorbuilderschalklineandmarkat24”centerline.
2)Cutoutpieceof22.5”x48,”measurein15”onfullsheet2drawtocornersfromcenterline.Makesecondcut,measuredown15.5”onpartsheetfromeachedge.Drawtwolinesasshown.
Sheet#1 Sheet#2
24”
24”
markcenterlineforreference
Sheet#1(partial) Sheet#2(full)22.5”
cuto
ffan
dsa
vefo
rtra
nsom
pat
tern
15.5”
15.5”
firstcuthere
15”mark
cut#
2
48”
10
15.5”
15.5”
3.5”
3.5”
AB
C
D
E
Sheet#1 Sheet#2
3)Measure3.5”on96”eachtransomside.Shownas“A”mark“B”mark.
4)Cutoutsides-centerwastebecomesplywoodbuttblocksandseatsupports.(Earleneverwastedanything)cutDtoBtoE,thenCtoAtoE.
5)Itisimportanttocheckfinalmeasurementsandmarkeachside.A+Cshouldbeidentical,B+Dthesameifonesideisslightlysmaller(howevernotwoBrockwayswerepreciselythesame)laythesmallersideontopoflargertraceline,cuttoexactshape.Slightdifferenceswillnotimpactskiffsconstruction.
A B
C D
73.5”
73.5”
70”
70”
96”
81”
96”
81”
11
Sidescannowbespliced-withapieceof1/2plywood-buttblockdoesnotextendthefullwidthbut4inchesshortofbottomsideedgetoppieceis18taperedto14.”Thefourinchesiswherethechinewillbeplaced.Earlewouldcutthesepiecesfromleftoverscrapproducedfromcuttingthesides.
Plywoodsplicemeasures18”x15”deepx14”(use1/2plywood).Note=ifyouplantoplaceaninteriorraila1x3pinestockwillwork-thenmodifysplicefor12”deep-leavetop3”clear.Asthiswillfurtherreducethesplicearea.Widenthesplicetopfrom18”to22.”
Glueandnailbuttblocksusing7/8”inchroofnails.20to30nailseachsplice-glueshouldbeepoxyresin(splicegoesontheinside).The“A”sidecontactsthewaterthespliceshouldbeonthe“C”sidewhichshouldbethevesselinterior.
Placespliceonsidetraceoutlines,applygenerouscoatingofepoxyresinwithintracedlines-(coatsplicepiecewithresin).Placeonside-matchtracedlinesnailatfourcornersmakingcertainthatthesplicedoesnotslipoutofposition.Finishingthenailingprocess.
Leave4”clearforchine
14”
18”
15”
Nails
Spaceforchinetobeplacedlater
12
Mold
Mosthullsarebuiltwithamoldtohelpmaintaintheshape.Earledidn’tuseamoldbutusedtemporarybraceswhichheplacedatstrategicpositions.ThisseemedtometobetheproductofdecadesofexperiencesoIsuggest(strongly)theconstructionofatemporarymold(asshowninthe16constructionguide).
Theforceatwhichhepushedthesebracesintookcourageaswellasskill.IstillhavementalimagesofEarlejumpingonthese!Anywaythemoldalthoughtemporaryiscompletelyreusable,soitcanbeloanedouttosomeoneorreusedmanytimes.
Mold Design
58”
18.5”
47”
Cutout1x4”notchforchine
Themoldmeasures58”top,47”bottomby18.5”highuse2x6material-seequickmethodbe-low.
2x6 58”long29”
cutofftoshape
Layoverandcuttoshape
18.5”2x6
2x648”long
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1)Cuttwopiecesof2x6spruceorfir,one58longon48’long,markcentersoflength.
2)Place18.5piecesof2x6atcentersandusingabuildersframingsquarefastentomarkan”H.”Checktoseeifsquare.
3)Longtwopiecesof2x6about25”longplacingeachedgeasshown,markwithpencilandcutfourtriangularpiecesout.
4)Fastenthe2x6sidestotheoriginalH,cutthemtolength,use2.5drywallscrewsorsimilartofasten.
5)Notchbottomcornersofmoldtoaccept1”x4”pinetrimaschine(actual3/4”x3.5”)
Mold Placement
Placestemandsidesectionstobebuiltbottomupallowexcessstemaboveandbelowsheets.Attachthebowsectionstothe4”x4”trimmedstemwithepoxyresin-nailusinga2.5”to3”gal-vanizedcommonnailsevery2”,about60nailstotal.Letdry.RigaSpanishwindlass(see16’guidesection)usinga5/16orlargerdacronorpolyblendloopofropearoundthesides.Placeapieceofscraplumberbetweentheloopholdropestogetherandtwist.Becareful!Thespringtensioncreatedhereistremendous!Asthesidesslowlycometogether,placethemoldintotheskiffasfollows.
18.5”
notchout
58”
47”
centerline
Mold Construction Details
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1)Attransomend-measure61.5inchesoneachtopplywoodedge.(Thevesselreachesmaxi-mumwidthhereof60.5”across)markwithpencilorchalk.
2)Measure58”oneachbottomplywoodedgeandmarkwithpencilorchalk.
3)Placemoldinsideskiffandnailintoplaceatmarks,donotnailallthewayonthismoldiseventuallyremoved.Placemoldasshownindiagram.
ContinuetodrawSpanishwindlassuntilsidescometobeabout48”apart.Securewindlassbytackingscraplumbertoholdsides.DO NOT RELEASE THE WINDLASS.Nowitstimetobuildthetransom.Thesideswillbegintoaccepta“set”-itisokaytoleaveforseveraldaysifinpropershape.
TransomDetails-twopieces3/4ACplywoodgluedtocreatea1.5”thicktransom.
The Spanish Windlass
Youmightwanttopracticemakingthetransomonthe1/2scrappiece22.5”x48”cutofffromproducingthetwosides.Everythingdescribedherecanbedoneonthe1/2”plywoodcutoutscrap.
58”
61.5”
moldnailedtosidesBow
48”
55”
A
B
plyside
NailsNails
plyside
A=Woodlever20”B=ContinuousropeloopC=2x4woodbraceNote:Rotatingtheleverwillshortentheropelengthpullingthesidestogether.Usecaution,theforcecanbesignificant.
C
Stern
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Twopieces48”widebyatleast22’highwillbeenoughroughmaterial.Seebottompaneldia-gramtosavematerial.
How to Start
Istartbyjustcuttingtwopiecesof3/4AC48”x24”
Markcenterlinevertically,measureoverhalfof47and43ontop,bottomedges,cutoffscrap.Thenmeasuredown3”andcut7”outfromcenterasshown.That14”x3”cutoutbecomestheoutboardseat.Measure21.5fromcenterforbottomdimension“43”2.5”cutofffromeachside.
Nowcomestheart.I’mconvincedthatEarlekeptpatternsheetstodrawtheshapes.Ican’timaginehimtakingthetimetotrytofairoffthetransomsides.Basically,takeaplasticstriporotherflexiblewoodstripanddrawthetransomfinishlines.
48”23.5”23.5”
22”
43”
4”7” 7”
21.5”21.5”
CutOffCutOff
20”
1/2”removedtoslightlytapereachoutsideedge
47”
22.0”16”
22.0”
14”
43”
Centerline
Trimoff2”
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Takethe18.5”x47”finalpieceandlayoutflat.
1)Drive2nailsatA”16”C18.5”E15.”Placeflexiblecurvesandmarklines-cutoutusingajigorsabersaw.(scrollsaw?)Whenthelinesareacceptable.Ihavefoundthatthinstrapsofwood-(doorstopmaterialwillwork)butdon’tcutshort,leavelongoverhangssettran-somontableifnecessary.Placestripbetweenthenails,tracealongcurve.
Remembernotwotransomsareexactlyalike,youcanchooseyourowncurveornocurve!
2)Thetransomhasaslightbottomtaperabout1/2”sotheoriginalmaximumheightisreducedto18”at“C”oftenfinalcutfromeachside.
Usingthissheetasapattern,traceoutasecondsheet(ifyouplantomakemore14”skiffs,traceouttwoadditionalpiecesandsavethisoneasthepattern.)
3)Oncethesecondsheetiscutout,laybothonworkingsurface.Covereachwithathincoatofepoxyresinoverlapeachothernailtogetherwith11/4”roofnailstocompletethetransom.
4)Afterthegluehascured,itisreadytobebeveledtoacceptthesides.Asthepieceswerecutflat(noangle),itwillbedifficulttoattachthesideswithoutdistortingthe1/2”plywoodsides.Thebevelhoweversmall,isimportantforcreatingpropercurvature.
Repeatthisside
Thinwood16”
1/2”15”
Cutto1/2”
AB C
DE
Drawline
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Oncethebevelisfinished(askillsawisfineforthisprocess).Planeorpowersandallothersidestomake“even.”
View of Transom Bevel from Above
Transom
StarboardSide
Sandtomakesmoothallsides
Portside3/8”to1/2inchbevelissufficient
3/8”to1/2”bevelissufficient
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Attaching the Transom
ReattachtheSpanishwindlasstightentotakethestainoffthetemporarybrace(thescrap2x4putintoholdthesides.)Keepingthepressureonthewindlass,removebraceandplacethetran-sominplace.Drivetwocommongalvanizednailsoneachside.Drawthewindlasssothatthetransomistightinplace–nailthetransominplace,butdonotnailalltheway,usingthesideasaguide,adjustsothetransomiseven.Itisimportantthattheinsideedgeofthetransommeettheplywoodsides.Becauseoftheangleofattachment,theoutsideedgeofthetransomwillbeabovethesides,that’sfineasthisaswellastheextramaterialofthestemwillberemovedtoformaflatsurfaceforthe3/4”plywoodbottom.Takingacrayonorpencil,makeamarkonedgeside.Thiswillhelpyoualignthepieceswhentheglueisonthemforfinalnailing.Loosenthewindlassslightlyandremovethenailsandtransom.Thenwiththeproperlypreparedresinglue,coatthesideswithinlinesandtransomedge.Replaceandthennailwith12galvanized2.5”#8commonnailseachside.
Whenbothsidesarenailedandtheglueisstillwet,takeaballpeenhammerandwiththeballendseteachnailatleast1/4”inchdeep.Filleachnailheadwithresinglue;thiswillkeepthewaterfrommakingdirectcontactwiththemetalnail.Doingthisprocedurethroughouttheconstruc-tionprocesswilladdabout5yearstothevessellife,(15years)insteadofflushnailingwithnosealer(otherthanpaint)insteadof10yearswithACplywood.Remember:ACplywoodisnotdesignedformarineconstructionandhasalimitedlifespan.Defects(notsevere)canbere-pairedwithmarineresin(seepage24fordetails).
Withgoodmaintenance,aplywoodskiffbuiltwithACcanlastupto20years.Marineplywoodhoweverismuchmoreexpensivebutcouldlast20to40years.MostBrockwayswereusedforrecreationalandcommercialfishingandweresubjectedtohardcontinuoususe.Anytimetheplywoodsurfaceisbrokenallowingwatertosaturatetheplywooditisharmfultotheskiff.Sincethiswasconstantwithcommercialfishing,after10yearsofharduse“justgetanotheronefromEarle”waswordalongthewaterfront.
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Skiff Widths and Details for Bottom Plywood and Seat Placement
This14-footskiffbottomisbuiltfrom3/4”ACplywood–“A”sidefaceswater.Thenextstepbeforethebottomistoinstallthechines1x4pineFlatstockoftenusedintrim.Itshouldbe#2withsmallknotsandnoobvioussplits.Skiffshouldbeplacedwiththebottomopeningup.
Take2lengths16’of1”x4”andplaceonoutsideofskiffsideswith4to8clamps.Marklengthsofpinelengthstofitinsideofskiff.Then,oncecuttolength,placeoninsidebeingcarefultoplaceintomold“slot”.Aswiththetransomandstemchineshouldbeslightlyabovepineside,asitalsowillbetrimmedfortheplywoodbottompanels.
60.5”59”
48”Bottom-3/4”plywood
Sides-1/2”ply-wood
StemBevels
FloorTimber-2”x4”
SheerClamp
Chine1x4
BevelofChine
A
B
Center
13/4”13/8”
A=B= 13/4”
10/16”eithersideofcenter
Keel
TopViews
20
Attaching the Chines
Allowingthechinestobeinthemoldandalongsides24hourswillhelpinthefinalprocess.Longerisbetterasthewoodwillbegintoacceptthe“set”or“take”theskiff’scurvature.Be-forethegluingprocessbegins,cut4to5temporarybraces–scrap2x4’sworkgreat.Thesewillbeplacedwhilethechinesdry.Theyhelptokeeptheskiffsshape.Toensurethepropershape,setupacenterlinestring(#21nylontwineissufficient)fromthemiddleofthestemtothemiddleofthestemtothecenterofthetransom.Distancefromthecentertothesidesshouldbeequal,butitispossibletoadjustwithbraces,wedgingtighttoadjustthesides’shape.Tochecktheskiff’sfinalshape,takeasightalongthecenterline.Removeonechineatatimecoverwithresinandnailwith1-inchroofingnails(60to80nailseachchine).Remember:keepthechineslightlyabovetheplywoodside.Thismaterialwillthenbetrimmedtoaccepttheplywoodbottom.Whilenailingthechine,usethewoodclamps–don’texpecttheroofingnailstoclosegapsbetweentheplywoodandchine.Thegluesurfacesshouldbetightbeforenailing.Themoreclampsthebetter!Toolrentalstorescouldbehelphere.(Ihaveusedasmanyastenwoodclampsperside.)
Preparing for the Bottom Panels.
Whenthechinesaredry,placetwopiecesofwood2’apartonthesides.Thesemustbeflushbe-forethebottomisattached.Reviewingwhatwascoveredbeforeexpecttotrimthechines,tran-som,andstem.Allsurfacesshouldbesmoothandflush-aflatstockacrossthevesselwillshow“high”spotsthatneedtobeplannedorifyouarecareful,useabeltsander(smallsizes).Youarefinishedwhenyoucanmovethatpieceofflatstockfromstemtotransformwithnospacelargerthan1/8”lessisbetter.Thatspacewillbeclosedduringtheapplicationofthemarineresinandnailingprocess.(Earleusedtotrimthechineswithahatchet-notrecommended-abeltsanderisbetter,butdon’toverdoit!)
Flatstockcancheckbothsides
Chine
PlywoodSide
Thesearetrimmedflush-1”x4”chine
1/2”Plywoodside
Flushtoac-cept3/4”ply-woodBottom
21
Sevenoreightinchpiece
48”Piece
Use8-footsheet
Floortimberis2x4(ABC)lumbertospanjointcanusea4x4ifdesired
Checking the Skiff’s Shape from Stern to Bow
Station
1 5”2 2’5”3 4’5”4 6’5”5 8’5”6 10’5”7 12’5”8 12’10”9 AtStem5”
Width(measurefromstern)
50.5”56.5”60.5”59”53”40.5”22.5”18.5”5”
Example:5”fromtransom,thevesselis50.5incheswiderailtorail.or6’5”fromTransomthewidthrailtorailis59”
Maximumrailtorailis60.5inches
MaximumonBottomis48”(incheswide)
RailtoRail
Stem
HalfWidthShown
A
B
C 96”
22
EarleBrockwaywouldhavebeenamusedtoseehowmuchtimeIspentontheshapeoftheskiff.Hecouldjustlookatthesidesandwithapoundhereandhammerhitthere,he’dconfiguretheshapebyeye.Thattakesyearsofpractice!Adjustingtheshapesoitisequaltothecenteringstringcanbeasomewhatfrustratingprocess.RememberthemeasurementsIprovideareonlyaguide–eachskiffisalittledifferent–thenextonemayhaveamoretaperedbow,flattersectionatthestern,etc.Idoknowonething,thesidesatthesplicecanbeachallengebecauseyouarebending1”ofplywoodinsteadofa1/2”sheet.Youmayneedtospendsometimeandanextrabraceheretogetthatdoubledareatoshapeup.Don’tbetimid;itwilltakesomebendingandpoundingtogettheskiffsshape.
OnethingIseeinthehomemadeBrockwayskiffsisaflatsectionatthesplice.Thevessel’sshapebottomupshouldbelikethatasshownonpage20.Thedotteddoublelinedownthemid-dlerepresentsthe2x4keel,whichisboltedonlast.The3crosspiecesrepresentthefloortim-bers,twoofwhichalsofunctionas“seams”forthe3/4”plywoodjoint.Whentheskiffisbottomupandallsurfacespreparedtoacceptthebottom,Earlewouldgatherupsomenailsandwouldplacethefirstsheetonthetransom.Takingafewnailshe’dtackthesheetalongthetransomandwalkforwardtobendthe3/4ply,tacknailingeverysooften.
Hewouldmarktheedgeofthesheetwithapencil,formingthecenterlineforthe2ndfloortim-ber(spaced4’apart).Placethesecondsheetnexttothefirst–tackingalongthechines–mark-ingthelocationofnextfloortimber.Whenthatwasdone–Earlewoulddrawalineleaving1/2”to5/8”extraonalledges–thiswasthelinetocutoutfortheskiff.Oncemarked,hewouldpulloffthesheetsandinstallthefloortimbers.2x4lumberworkswellbutrememberthemarks.Youmustcenterthisontheplywoodseamleavingonly3/4”oneachinwhichtonail.Manypeoplelikealittleextrawidth–4x4isokay.Itaddsweighttotheskiff,butdoesgiveyoualittleextranailingroom.Aswiththechines,stem,andtransom,itneedstobeflushwithallsurfacesbeforenailingthebottom.
Correctseaminmiddle
Incorrectseamoffedge
Floortimber2x4
Floortimber2x4
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PlywoodSide
Chine
FloorTimber
PlywoodSide
CenterMarkforTimber
NoSpace
About the Plywood Bottom Panels.
Itwilltaketwo4x8panelsof3/4ACplywoodforthebottom.Thelargesheetfromthetransomismostlyused,butthemiddlepieceisa4x4piece.Thetwotransompiecescanbecutfromtheotherhalf.Theverysmallbowpiececanbecutfromscrap.Inthisway,onlytwosheetsneedtobepurchased.Remember:Earlewasverycost-consciousaboutmaterials,soplansreflectthe“most”forthe“least”.
Installing the Floor Timbers.
Foranexperiencedboatbuilder,shapingapieceofsquarestockwitheachendhavingataperandanglecutiseasy.Forothers,andIincludemyselfinthiscategory,trialanderrorseemstoruletheday.(Takeawaytheflairandcurveanditiseasy!)
Eachfloortimbermustfittightagainstthechinesandatthemark.Aquickreviewwillshowthattopofthefloortimberislongerthanthebottom.Thisdimensioncanbemeasured-writethetopandbottommeasurementstothefloortimbercentermark.Butthat’sthedistanceonlyatthecen-termark!Thecurvatureoftheskiffthatwillbeatoneedgeofthefloortimber(towardthebow)willbelessanditwillbemoretowardthestern.Notallowingfromthisdifferencewillcreateaspace–whichwillweakenthefloortimber.
Timber,chine,andplysideallneedtobeflush.
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Method #1 Afteraboutadozenwasted2x4’s(onesidewouldbeperfecttheotheroneinchshort,etc.),I
cameupwithamethodwhichmaysaveyousometime.It’salittleembarrassingtodescribe,butwoodworkingisnotaskillIcanbragabout.Itakeapieceof1x4pinesquarestockandnailittothesidescenteringthefloortimbermarks.Then,takinga2x4thatisabout1’shortoneachside,screwthe2x4tothepinestock,againcenteringfortheproperposition.Icutfourstripsof1/4”luanplywood3.5”x2’andplacethemagainstthechine,usingajigsawandapencil,Itracealine,followingthechineonthetrimminguntilitisaveryclosefit.ThenIscrewitintothe2x4.Afterallfourpiecesarefixedtothe2x4,Iremoveitandthatisthepat-ternIuse.Thissoundsalittletimeconsuming,anditis.Onlyafterhoursoffrustration,doesitbecomeawayout.AsIsaidbefore,Earlewouldfindallofthisveryhumorous;hewouldexaminetheopening,takearoughmeasurement,settheangelonhisskillsaw,andwithtwoquickcuts,producethefloortimber.
Method #2 Thiscameupacoupleoftimes.Placethefloortimbersfirstandthenmaketheplywoodfit
them.Iguesswhateverworks,butIcouldquicklyseebuyinganadditionalsheetof3/4ply-wood.Againitmightbeworthit.(Ithinkitis.)
Method #3 Inviteoverafriendwhoisaskilledcarpenter.Onceallthefloortimbersareinandflushwith
thechine,bowandtransom,makea1/2”x1/2”notchatthechine.Thiswillallowwatertodrainalongtheflooronesectiontoanother.
Attaching the Plywood Panels
Cutoutthebottomplywoodsectionsandplacethemonskifftocheckdimensions.Ifproper,ap-plygenerousamountsofmarineresintotransom,andchinestofirstfloortimber.Oncetheglueisapplied,placethesheetandquicklynailitintothetransom–placestones,weightsetc.,onplywoodtomakeitconformtothesides.Iliketostandonthesheetandwithaballpeenham-merandabagof8-pennynails.Startatthetransomandworkouttoeachchinefloortimber#1alternatingeachchinequicklyandfinishonfloortimber#2.Repeatwithsecondsection.And
Notchallowswatertodrainfromonesectiontoanother
FloorTimber
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usingapieceofscrap,thebowsectiononfloortimber#3.Thenailingprocessneedstobefairlyrapidasthegluebondshouldcureonlyafterbeingnailedwithnailsplacedevery2.5to3inches.Us-ingaballpeenhammer,recessthenailsandfillwithresin.Don’tbesurprisedifthenailholeneedstobefilledseveraltimes;actuallythatisgoodasitsealstheexposedplys.Iliketofillthemflushwiththerestoftheplywood.Earlealsocautionedmeagainstcuttingtheexcessoffthe3/4”sheetbottom.Helikedtoleaveatleast1/2”extratoberoundedoff–calleditabuilt-in“fender”.Thisedgecanberoundedwithsandpaperandpaintedwithresin.OnoneoftheskiffsIpreparedthisway,aftertenyears,thenailswererustedalmosttothebreakingpoint,buttheknotsontheplywoodpaintedwithresinwereasgoodasnew.Seriousflawsintheplywoodcanbefixedwithplysliversorsectionsofplysimilartopatchesinhigh-grademarineplywood.ThissoundsliketryingtoturnanACpanelintosomethingbetteranditis.The16-footskiffguidehasanentiresectiononrepairingandstabilizingknots,edges,etc.
Can You Fiberglass a Brockway?
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Yes,andIhaveseenitdone.Onewordofcautionhowever,whenglassingandapplyingtheresin,thecurecanbe“uneven”.Inareasthatthegluedidn’tpenetrate,ittendstocrack,lettingwaterinbetweentheclothandtheplywood.IhaveseenBrockwaysrotoutfasterbecausetheywerefiberglassed,hadacrack,andhadwatertrappedbetweentheoutsidefiberglasscoatingandtheplywood.Sometimeswatercouldgototwoorthreefeetfromthecrackmakingrepairsdifficult.Morethanonce,Ihadtoremovetheclothaltogethertofindoutwhatwascausingthedamage.Howeverapplyinga4”bandoffiberglasstapeattheoutsidechineedgedidseemtohelp,whichwasdoneonalotofBrockways.
Finishing the Skiff
Threemajorproceduresneedtobefinished:toprails(sheerclamps),thekeel,andthethreeseats(thwarts).Sincethevesselisstillupsidedown,letsgotothekeelfirst.Earleuseda2x4or2x6pieceofDougFirstructurallumber.Hewouldputoutseverallongpieces,ingoodshape,freeofanyseriousknotswhichmaycrackorbreak,wedgingoneendonarockorbarrel,placingstonesontheotherendtobenditintheopenair.Gettingthepropersetcouldtakeweeksormonthstoobtain,especiallyforchines,railsandheavykeels.Along2x4canbemadeusableintwotothreedays–thebendneededforthekeelislessandthemanyfastenersassistwiththisprocess.Forthisskiff,an18-footgreenDouglasFir#22x4issufficient.Avoidlumberwithseriouscracksorlargeknotsinthemiddle.Ithasbeenmyexperiencethatthesewillbreakabouthalf-waythroughtheprocesssoitsjustnotworthit.Pickoutagoodone!UsingasimilarmethodasEarle(althoughancient)iseffective.Iuseda125-poundmushroomanchoroverabarreltobenda20-foot2x4stakedtotheground.Greenlumberhasmoremoistureandbendsmoreeasily.Avoiddriedoutlumber-itcracks.
ProbablythemostcommonmemoryofowningaBrockwayisthenotsopleasantmemoryofroofingtarandlotsofit.Earlewasextremelygenerousinitsuse,usuallyapplyingitwithastick(“Sticksarecheap!”Hewouldtellme).Anyway,acommonphraseaboutbuildingaBrockwaywastwodaystopaintit,twoweekstoremovethetarbeforeyoucouldpaint.Itwouldn’ttaketwoweeks,butitwasquiteaprocess.Evenyearslater,onahotdaythetarwouldoozeout.Earleusedthetartosealjointsandkeepwaterout.Attimes,itseemedasthoughtheentireboatwascoveredbytar.(ThoseofyouwhoownedonewillknowwhatImean.)Idon’tusetarex-
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The SeatsTheseatsonthis14-footBrockwaywerefromtwotypesofbuildingmaterials,therearseatx2x12Dfirframingorstructurallumberthemiddleandbowseatsfromstairtreadmaterial.Earledidn’tgotothelumberyardthatmuch.LocalcontractorswhohadsurplusmaterialswouldsellthemtoEarle.Someonemostlikelyhadsomeextrastairtreadsandthat’showtheyendedupintheskiff.Isuggestputtingthetransom&bowseatsinfirstthenremovingthemoldandinstall-ingthemiddlesheet.Someconstructionnotes:
This14-footskiffwasold–noenclosedspaceswithfoamfloatation.Isupportthefloatation,butnotinsealedcompartments.RarelyhaveIseenthesecompletelywaterproof.Theyleak,allowingwaterandmoisturetorotthewood.Instead,Ilikeenclosedfloatationbutnotsealedallowingthecompartmenttodryout.OftenIputinafloortimberatthetransom.Itisoptional,butbuildsaverystrongtransomandassistswiththefloatationcompartment.Toprovidefloatation,Iusea12”x10”styrofoamlogintwosectionsbetweenthecenterseatsupport.Toallowthisareatodry,Ibuildtwosectionsofafalsefloor–1/2”pressuretreatedplywoodwith1/2”diameterholesontwopiecesofpressuretreated2x4.Apieceof2x6isusedasacleattoholdthestyrofoamloginplace.Thepressuretreatedplywoodisattachedtothefloortimberwith1/4bolts.Thecleatsarealsoattachedwith1/4”bolts.Thespacebetweentheseatandtransomallowthefalsefloortoberemoved.Thisprovidestwopiecesabout22”wideoneachsideoftherearseatsupport.Theconceptistoallowforquickremovalandallowwatertoexitquicklyfromthisarea.Theareaundertheseatshouldbecleaned,driedandpaintedeveryyear.
ceptforattachingthekeelandhereitmakessense.Ifyouusedtheskiffsfromtheshorethekeeltakesalotofabuse.(Sand,rocks,gravel,etc.)Itwascommontoruboffthecopperbottompaintallowingthemarineborers(shipworms)inthekeel.Oncein,itisonlyamatteroftimebe-forethekeelneedstobereplaced.Ifthekeelwasgluedtothebottom,itwouldtakemanyhourstochiselthekeeloff.Instead(inthiscase,IagreewithMr.Brockway),putagenerouscoatingoftar(canbethetubeform)onthe2x4andontheskiff’scenter.Nailtwo12-pennyoneachfloortimberanduseaseriesof1/2”galvanizedcarriageboltsbetweenthefloortimbers(washerandnutonthefloor)tofastenthekeeltotheskiff.Startatthetransom,endatthebow,carefullycuttingofftheexcessfromthebowleavingalittleexcesssmoothtoshape.Ifthekeelneedstobereplaced,removeallboltsandpulloutthenailsfromthetransomandfloortimbers.Cleanoffanyoldtarandre-coatwithnewtar.Installthenewkeel.Ioncereplacedthekeelona14–footskiffinlessthantwohours.Itwouldhavetakenmuchlongerifthekeelhadbeengluedon.
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Seat Details
Center seat:5”belowsidesandisplacedatcenterofmold;hascentersupport.
Rear seat:Slantedtowardthetransomtoshedwater;hasacentersupportwhichisfastenedtotransom.
Bow seat:8”belowsidescenterlineis49”fromstem.Seatconsistsoftwopiecesof1.5x11.5”stairtreadsflatedgetoflatedge.Attachsectionofstyrofoamlogunderseat–canusestrapsorboxintoenclose.
General: Allseatsuseacentersupport.Asectionof2x4isboltedtothekeelthroughbottomsup-portandisattachedtoitandtheseat.Allseatssupportedby1x4pinestockgluedandnailedtothesides.Theseatsrestonthesescrapsandnailtoit.Alledgesarenailedthroughthe1/2”plywoodsides.Edgenailingtheseatisnotenoughbutusethescrapsofwoodandalsonailfromthesideintotheseat.
Keel(applytarfirst)
2x4lagboltintothekeel
StairTreadSeat
Sectionoffloortreadassupport
3/4”Bottom
5” 17”
16”
Cleat
Bottom
PT1/2”plyTransom
Seat2x12Styrofoam
Additionalfloortimberattran-somforextrastrength(optional)
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Allseatsaresupportedby1x4pinestockgluedandnailedtothesides.Theseatsrestonthesescrapsandnailtoit.Allalsoedgenailedthroughthe1/2”plywoodsides.Edgenailingtheseatisnotenough,butusethescrapsofwoodandalsonailfromthesideintotheseat.(seediagrambelow)
Nails
Stairtreadseat
Seatsupportglueintoplace
Chine
3/4”Plybottom
Nails
1/2”Plyside
Seat Dimensionsremember:everyskiffisdifferent,sotreatthesemeasurementsasapproximations
Roundededge
Roundededge
Floatationunderseat
28.5
35.5atCenter
42.535.5
49.5”
48.5”atCenter
47”
SternSlightTaper
Floatationunderseat
CenterOnePieceSlightTaper
55”Trimto54.5”
55”atCenter
55”Trimto54.5”
Iputthegastanksunderthemiddleseat
Bowseat
Middleseat
Transomseat
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Attaching the Rails
Thefinalstepbeforepaintpreparationisattachingtherails.Mostskiffshada1x4pinerailontheoutsideplywoodedge.Withthetemporarybracesintactandtheskiffs’shapestable,takea16-foot#2pine–againfreeofsplitsorlargeknots.Bendthestockalongtherailwithclampssimilartothechineprocedures.Bendtheentirelength;youmightwanttodotheothersideandletthemsitforacoupleofdays.Ifyoudothis,itwillmakethenailingprocesswith1-inchroofingnailsandmarineresineasier.Tofasten,coattheentirenailandplywoodsidewhereitwillbeplacedwithresinglue.Clampintopositionandquicklynail,establishingapatterntworowsabouteverytwotothreeinches.Uselargernailsintothestemandtransom.Completetheotherside.Nospacesshouldbeobservedbetweenthepinerailandplywood.Ifaspaceisseen,quicklyputaclamponthatspot.Aftertherailisdry,removeclamps.SometimesEarlewouldputinaninteriorrail–thiswouldrequiresatopsplice3.5”belowplyside(mentionedearlier).Itproducesareallystrongrail3/4-pine1/2ply,3/4pine“sandwich”.Tofinishtherail,Itake3”plasticnarrowwallpipe(stelpath)andcutdowntheentirelengthwithahacksaw.Openingthecut,Islipitovertheentirelength;smallbronzenailsnailedtotherailwouldkeepthepipeinplace.Thisproducesagood“rubrail”forhaulinglobsterpotsorseedoysterdredges.Withoutit,thesoftpine(therails)wouldbetornupinamatterofdays.
Final Details
Oncetheskiffisconstructed,dotakethetimetoinspecttheplywoodsides.Anydefects,holes,looseknotsshouldberepairedwithplypatchesandmarineresin.Afewhoursofplywoodrepairscanaddyearsofusablelifetheskiff.Amarineenamelpaintonallsurfaces(primerplustwoadditionalcoats)willsealandprotecttheskiff.Antifoulingpaintonthebottomprotectstheskifffromgrowthandmarineworms.Remembersafetycomesfirst!Followallsafetytoolandequipmentprocedures.MakecertainthatthevesselfollowsallStateandCoastGuardRegulationsforsafeoperation.Ihopethatthisworkshopwasinterestingtoyou.WewelcomecommentsaboutthisworkshoporanyotherShortCourseIndustryWorkshop,pleasemailcommentsto: AdultEducationprogram,
VocationalAgricultureDept.TheSoundSchool
60SouthWaterStreetNewHaven,CT06519
Thispublicationistobeusedforeducationalpurposes.Copiesmaybeproduced,pleaserefer-enceauthors.Thankyou
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Additionss/Corrections to th 14-Foot Brockway Construction GuideTimothyC.Visel,May2008TheSoundSchoolAdultEducation&OutreachProgram
Buiding a 14-Foot Brockway by Tim and Willard Visel
In2005,Istartedtobuilda14-footBrockwaywithmyson,Willard.Wecutoutthesidesfromtwosheetsof½”plywood,trimmeda4X4tomakethestempieceandWillardgluedthetwosidestoit.That’sasfaraswegot,itjustwasn’tgoingtogetherfastenoughforus.Weputthesidesandstemassemblyasideintheyard,andthereitsatforthreeyears.
Inthemeantime,wepurchaseda12-footaluminumlakeskiff,alight,butserviceablefishingplatform,easytotrailerandlaunch.Oneafternoon,wehadtwolargebluefishhookedandsawthelookofamazementofsurroundingboatersstaringatusasweturnedtoseeourmetalcraftheadingtowardsixfootwavesbeforeareef.Wegotoutofharm’swaybyaninstantandboatedbothblues.But,thelookofsix-footwavesagainstour14-inchhightransomleft,astheysay,alifelongmemory.Westarteddiscussingalargerboatlaterthatday.Thatfall,wespentlookingatboats,eitherthesidesweretoolow(weliketostandwhilecasting)ortheboatwasjusttooheavy–severalhundredpounds.Wealsolookedatoutboardrequirementsandofcoursefuelcosts.Wewantedsomethingthatgaveusamorestableplatform,ahullwithnotalotofresis-tanceforpower/fueleconomy,withgoodhighsides.Afterafallandwinterspentlooking,wecametotheconclusion:finishtheBrockway.Ithadallthedesignfeatureswedesired,astableplatform,highsidesfortheoftenunpredictableLongIslandSound,somethingthatwaseasilypowered,withamodestoutboardandnotthatheavy.Laterthatfall,wemovedthestemandsideassemblybackontoouroutsidewooddeck.Duringthetime,wegluedandnailedthesides;theplywoodhad“set,”sotryingtogetthesidesuprighttooktwomonthsofpressure,butslowly,wewereabletogetthembacktotheshapeweneeded.Mr.Brockwaybuilthisboatsoutside,sotheflatdeckbecameourworkingarea.
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Webuiltthemoldshownonpage13andplaceditintheappropriateposition,theexcessstemweplacedoverthedeckinahole.Tomaintaintheshape,weattachedaseriesof2X4stationstothedeckwithscrewsonwhichtoplaceblockstoholdtheskiffinposition.Themoldwasat-tachedtothe2x4belowit,andthesidesnailedtothemold.Thiscreatedafixedframetolocktheskiffintoposition.Wehadaproblemwiththismethodwhenweattachedthetransom.Wehadtoreleasethesidestoliftthembothup.IthenrealizedwhyEarleBrockwaywouldpoundthestemintothegroundandsetthetransomwithironstakes.Hecouldlifttheskiffatanytime,noadjustmentsnecessary.
TheSpanishwindlassshownonpage14wasachallenge,nomatterhowwetried;wecouldn’tgetthesidestothemold.Ifeelthe3-yeardelayhadsomethingtodowithit
Thesideshadbeenapartandthewoodhaddried.Aswepulledthesides,wejustcouldn’tgetthemtothe47widebottomofthemoldsoourskiffis51wideatthatpartwewidenedthemoldbottom4inchesandkeepthetopwidththesame.Thiscreatedawideversionofthe14-footmodel.IrealizewhyEarlewanted47atthiswidth,½leftforeachplywoodedge,whichhefelt,wasimportantbutalsoforeconomyofmaterialswhichMr.Brockwayturnedintoascience.Butthechangeinwidthmeantextraplywoodwouldbeneededforthebottom–Earlwouldhaveusedalongwholesheet,stayingwithinthestandard48width,butweusedtwocrosssheetswhichdictatedofcourse,theplacementofourfloortimbersfourfeetapart.Thisrequiredthreesheetsofbottomplywood,insteadoftwo.Weputarearseatnexttothetransom,themiddleseat,justforwardofthefirstframesetandadoubleseat,(squareedgetosquareedge)justfor-wardofthesecondsetofframes.
Bottom and Transom Changes
Insteadoftheusual¾”sub-floorplywoodwhichEarlused,wepurchasedabetterquality5/8inchplywoodforthebottom(3sheets4x8).Thetransomwastwopiecesof¾marineplywoodlaminatedtogetherforthefull1.5”width.Thechinewasstrengthened(Willard’ssuggestion)withanidenticalpieceof½”pineontheoutsideedge.Hewasconcernedthatthe½plywoodand¾chinewasn’t“beefy”enough.Whensandedsmooth,thatprovidedabottom-nailingsur-faceof2”.
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Ihadseenthisdonebefore,soitwaswithintheBrockwaystyle.Itdidstrengthenthisareasub-stantially.Wediscoveredamajormistakeinthetransomplans.Theplywoodsideswereabout15incheshighwhichEarllappeda2x6over2inchesofeachside,makingtheactualheightofthetransomorside18.5inches.Weincreasedthatto20inchesbyusinga2x10x¾”pineplank,followedasecond2x5x¾”pineoverthat(whichformedthefinishedrails).Thisisalsoanadditionalpieceofwoodthatstrengthenedthetoprailarea.(Thehigherthannormalsideswasstillacarryoverfromour6-footwaveencounter).Theoriginalplansshowedthetrimmedorroundedtransomat16”high,butwhenyougotoattachtherail,thereisnowoodtonailto—ob-viouslyamistake--that16shouldbe18.5,whichweincreasedto20.Tohavea20sideandsome“tumblehome”inthetransom,thematerialneedstobeatleast22”high.(Roundoffthe22”to20”.)Inaddition,weaddedaside2x4ateachtransomedgetoprovideextrastrength,sowhenthesideswerenailed,wehada3”nailingsurface.
Supplies and Materials:
WeusedMarinepolyesterresinforallgluing–chines,nails,thwartsupports,etc.(2gallons).(Donotglueframesorkeel.)Weappliedthincoatsbetweencleanwoodsurfaces,usedgal-vanizedcarriageboltstoattachthwartsupports,galvanizedhardwareforgroundtackle-rings,cleats,etc.Toattachthechines,andrails,weusedamixtureofroofingnailsandcoateddeckscrews.Mr.Brockwaydidn’tusescrews,justnails,butweusedamix.
Thekeelandframesareboltedwithtar,notresin;Earleinsistedthatthiswasabetterpractice–keelsoftenrubthebeachandthecopperbottompainteasilyscrappedoff.Ontwooccasions,I“lost”thekeelonour16-footskiffstomarinewoodborers(worms).Toremovethekeelwasamucheasiertaskwithtar–removethebolts,andpulloutthestemandtransomnails.Ifithadbeenglued,Icouldseehours,ifwehadtousethewoodchisel.
The Seats
WeagainusedthetraditionalBrockwayseatmaterial,standardstairthread11.25”wideby11/8”thick,bullnoseononeedge.IdiscoveredthisbymistakethinkingthatEarlhadtakenthetimetosmoothoneedge–hedidn’t.Thematerialjustcamethatway.Wepurchasedtwo12-footlengthsandhadabout4leftover.
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General Comments
Weusedalotofmarineresintorepairdefectsintheplywood:cracks,voids(whichwerefixedwithplywoodslivers);looseknots.Wefilledthemwiththetwopartresinandsandedtheply-woodsmooth.Allcutplywoodedgeswerealsosealed,whichagainMr.Brockwayfeltwasveryimportant,especiallythe½”extraonthebottom.Hesawpeoplecutthisedgeoffflushwiththesides,whichEarlfeltwasamistake.The½”roundededgewasabuilt-in“bumper”incaseofhits,whichinourlobsteroperation,werefrequent.Weneverhadanedgegobad,however.So,resistthetemptation.Wealwayskeptthisroundededgeingoodcondition.
TruetoBrockwaystyle,wedidn’tgluetheframestothefloortimbers,butusedroofingtar–(caulkguntubes).Becareful–alittlebitgoesalongwayasanyonewhoownedaBrockwaycan“attest.”Thesayingusedto“twoweekstocleanoffthetarandtwodaystopaint.”ThetarMr.Brockwayfeltwasa“shockabsorber,”withtheframes.Ifahugehitoccurred,theframeswouldmoveinsteadofsplinteringorcrushing.Ididseethishappenandanoysterscowtookadirecthitandtheframesdidmoveandnotcompletelybreak.Hefeltthatiftheyhadbeenglued,theplywoodsideswouldhavesplintered,thehitboatdidn’tsink,buttheframeshadallsplit,soinafewhoursafterthenewframeswereinstalled,thescowwasasgoodasnew.
Onethingwelearned,isthatabeltsanderwasindispensable;wedidalotofsanding(Willard,mostly),shapingandjustgrinding.Asmallbeltsanderisamust!Wehadasmallsabersaw,powermitersaw,electricdrillandskillsawtoroundouttheelectrictools.AdozenCclamps,metal--wereahugehelpwithallgluing,chine,rails,supportsandtransom.(ItisinterestingtonotethatEarlwasslowtoacceptelectrictools,buteventuallyboughtadrillandskillsaw.Be-fore1971,itwasmostlybyhand.
Wefinishedofftheskiffwithgoodqualityoilbasepaint.Thebottomgottwocoatsofcopperbasedpaint.Goodluckandgreatfishing!
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Copiesofthe14-footGuideandtheoriginal16-footBrockwaySkiffplansareavailablefrom:
SusanWeberAdultEducationandOutreachCoordinatorTheSoundSchoolRegionalVocationalAquacultureCenter60So.WaterStreet,NewHaven,CT06519
Phone:2039466875Fax:2039466156Email:susan.weber@new-haven.k12.ct.us
Note:Ourschoolwebsite:www.soundschool.comhasBrockwayplansthatcanbedownloadedonyourcomputer.ComingsoonareaPowerPointofpicturesofactualconstructionofaBrock-wayboat.
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Twopieces48”widebyatleast22’highwillbeenoughroughmaterial.Seebottompaneldia-gramtosavematerial.
How to Start
Istartbyjustcuttingtwopiecesof3/4AC48”x24”Markcenterlinevertically,measureoverhalfof47and43ontop,bottomedges,cutoffscrap.Thenmeasuredown3”andcut7”outfromcenterasshown.That14”x3”cutoutbecomestheoutboardseat.Measure21.5fromcenterforbottomdimension“43”2.5”cutofffromeachside.
Nowcomestheart.I’mconvincedthatEarlekeptpatternsheetstodrawtheshapes.Ican’timaginehimtakingthetimetotrytofairoffthetransomsides.Basically,takeaplasticstriporotherflexiblewoodstripanddrawthetransomfinishlines.
20”
1/2”removedtoslightlytapereachoutsideedge
47”
22.0”16”
22.0”
14”
43”
48”
23.5”23.5”
22”
43”
4”7” 7”
21.5”21.5”
CutOffCutOff
Corrected Page 15; July 2008 TrimOff2”
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NationalFishermanPOBox7438Portland,ME04112-7438Faxlettersto(207)842-5603Email:nationalfisherman@divcom.com
“MailBuoy”
BrockwayTraditionisTimeless
ItwasterrifictoseeMichaelCrowley’sstoryaboutBrockway-styleskiffs.(NF,Sept07,pg.38).IalwaysenjoyreadingaboutorseeingBrockwayskiffsfromSouthernMainetotheChesapeakeBay.It’sbeenoveradecadesincetheflatironsandhammersfellsilentattheformerBrockwayBoatWorks,locatedinFloralPark,OldSaybrook,Connecticut,butinterestinEarlBrockway’sfamily’sdesignandconstructiontechniquescontinuestogrow.IwasfortunatetospendalotoftimewithEarlBrockway,thelastoffivegenerationsofConnecticutRiverBrockwayboatbuild-ers.VisitorstothelowerConnecticutRiverwillfind“Brockway’sReach,”“Brockway’sIsland”and“BrockwayFerryRoad”--allreferencingthemaritimeimpactofhisfamily.Whatisn’tsowellknownisMr.Brockway’sgenerosityandinterestinsmallboatfishermenregionallyandinternationally.
AccordingtoEarl,theBrockwayskiffandscowevolvedfromthe1920’sConnecticutRiverturtle,duckandshadfisheries.Manyoftheseusesincludedduck/waterfowlhuntinginthewin-ter,sodesirablefeaturesincludedstability,easeofmaneuverabilityandshallowdrafts.ThefirstBrockwayskiffswereoftraditionaldesign-plankedconstruction,hardchinenotunlikethesmallworkskiffsofNianticBayandNoank,CT.Originally,aboatforbayandriver,thefamilybeganexperimentingwithplywoodinthe1940’s,firstreplacingthebottomandlater,thesides.Thefirstallplywoodversionswhichincludedthetransomassembly,cameoutinthe1950’s.WhatwasamazingtoEarlisthatcustomerswantedhighersidesfortheskiffsandsotheybecameprevalentoutsideriversandbays.Aftera“high-sided”versionwasadded,theskiffs’popular-itysoared.Scowboatscontinuedinthetraditionallowerprofilesandwereusedforoystering,lobsteringandofcourse,shadfishing.Theywereknownfortheirstrength,durability,holdingcapacity,easeofrepairandmaintenance.Fishermenlovedthelowerinitialcost,(theycame“unfinished”),andyouhadtoprovideyourownpaintingandremovetheextratar.
In1972,IpurchasedmyfirstBrockwaywithmybrotherRaymond.Weusedthemformanyinshorefisheries,andsoonrealizedwhy“Earlcouldn’tmakeenoughofthem;”althoughtheywereslower,theboatwastough,couldtakealotofpunishmentfromthegearandwasagoodseaboat,andmostimportantly,reliable.
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Wewouldownseveralovertheyears.In1981,whenaninternationalrequestwasissuedforasmall,simplyconstructed,strongplywoodworkboat,aspartoftheUnitedNations’responsetofloodsinAsia,wesubmittedtheBrockwaydesign.Ayearlater,theconstructionmanualply-woodworkboatsforsmall-scalefisheriesandphotographsbyRaymondappearedayearlater.Themanualwasdesignedfordisasterrelief,PeaceCorpsandUSA.I.D.fisheriesextensionefforts.The“Brockway”designwouldsoonbecomeavailableworldwide.Infact,myownsonevensawoneonatriptoFijiin2005!Earldidn’twantorexpectanythingforthedesign–hissimpleresponsewas“CommercialFishermenneedhelponceinawhile,”followedby,“Ihopetheywillcomeandvisitmesomeday.”And,somedid.AfewyearsbeforeEarlpassedaway,avisitorfromHaiticametoseehimwithphotographs,andontheHaitianbeachwereseveral“Brockway’s.”Hewantedtovisitthemanwhohadhelpedhisvillage.
ThatwasthetypeofmanthatMr.Brockwaywas–veryunassumingincharacterandalwaysamazedatthepopularityofhisboats.The16’“extra–wideskiffplans”wentintoextraprint-ings.TheBrockwaystyleskiffwillmostlikelybeoneofthemostpopularandeasilyrecogniz-ableinshorefishingboatsofNewEngland.ItwasgreattoseethatpopularitycontinuedandtoreadaboutthelegacyofEarlBrockway.
TimothyC.ViselAquacultureCoordinatorTheSoundSchoolRegionalVocationalAquacultureCenter17SeaStreetNewHaven,CT06519
Phone:2039467106
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BrockwayPlansfor14’skiffandfor16’skiffareavailableforfree!Contact:SusanWeberTheSoundSchoolAquacultureCenter17SeaStreetNewHaven,CT06519
Susan.Weber@new-haven.k12.ct.us
2039466875(phone)203-946-6156(fax)
Donationforpostageisappreciated.