Tuesday, September 6, 2011

Improved deck supports

The deck curve at bulkhead #2 is a full 1" which means that our 1" wide deck supports would be too thin on the ends to offer any support. You see the outline of the 1" support against the curve at the top of the bulkhead here.

I could have just added a strip at the bottom to make the whole piece taller, but I thought i would do something a little stronger and lighter. I actually gave the solution away in the first photo, it's the triangular pieces on the far right. They will fit below the full length strip making the whole piece about 1" thick and orienting the grain properly at the edges. Not as fancy as laminating up a curved support but more than enough for a stitch-and-glue beach cat.

I started by marking out the shape on a scrap strip of the 1" x 1/2" fir.

I wasn't sure how to cut this at first, but finally decided to just do it by hand with my new Japanese pull saw. The more I use that saw the more I think power tools are over rated.

And here it is all glued up and again held with staples. Staples aren't the prettiest, but it worked and it's all going to be painted later anyway.

Finally, here it is with the glue dried and two coats of epoxy.

One more afternoon of glueing and all the bulkheads will be assembled and coated. I'll trim the top edges on the router table and they'll be ready for stitching into the hulls.


  1. That's what the 1/2"x 1-1/2" stock in the materials list is intended for.

  2. Thanks for the comment. We knew that but when ripping the boards down it was less wasteful to make all 1" x 1/2" strips. This was the only place it would be an issue (I think!) and we would have wasted a lot of wood otherwise.