brockwayfull

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

1�

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”

1�

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:[email protected]

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:[email protected]

“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

[email protected]

2039466875(phone)203-946-6156(fax)

Donationforpostageisappreciated.