Week 44: Staining Wales

I wanted to get my work done on Saturday, since Sunday was supposed to be rainy. But the more I thought about it, the more it made sense to clean out the garage and rearrange how the boat was stored in there, since the construction of the hull is complete. The next few weeks will be staining and painting, where it makes more sense to apply the messy liquids to the boat in one place rather than try to move her in and out of the garage. I especially don’t want to move her while there’s some stain or paint drying. I don’t want to accidentally grab where there’s wet paint or conk into the side of the garage moving her back inside.

So that took almost all of my time on Saturday, but I got a bunch of tools out the garage and the boat back in the garage upright and facing forward ready for finishing.

Right side up and facing out

First step after that, though, was taping off parts where I didn’t want stain to go. Right now I’m just staining the wales (and breast hook and quarter knees), so that meant a line of tape under the gunwales on the outside and the inwales on the inside. The gunwales were a lot easier, where I could just sit on a stool and scoot along as I applied the masking tape. The inwales were the tough part, since I had to stand outside the boat and couldn’t very well see underneath the wales. I suppose, thinking about it now, that I maybe could have lain inside the boat, underneath the wales, but, no, that wouldn’t do with the boat on sawhorses. I don’t imagine I’ll be getting in the boat until she’s on the water.

I only managed a bit of the interior taping on Saturday, so then I was back at it on Sunday afternoon. It was indeed rainy on Sunday, all day rain, so I was pleased that I had taken the time on Saturday to arrange things so conveniently in the garage. After finally taping off under all the wales, I also taped up a 0.7 mil plastic drop cloth inside the boat to prevent any drips or spills from staining anywhere that’s going to be painted.

Oh, and I did do a little more sanding, using 100 grit to touch up the wales where there were dents from the saw horses from turning the boat over and/or storing it upside down on the sawhorses. From now on I need to use padding when handling the boat on the sawhorses or on the furniture dolly. I don’t want any more unnecessary dings. And I used a single sheet with a block of 220 grit to give a final smoothness to the wales.

Taped and ready

And with that it was ready to stain. I’d vacillated a bit on what color stain I wanted on the wood. I’d originally thought about using an oak stain but then more recently decided that it was too gray. I finally went with a cedar stain.

Putting it on a test piece, though, it looked way, way too orange. I immediately regretted my choice. I cursed my lot in life. I rued the day I was even born.

I’d already spent twenty bucks on the can, though, so I went ahead and put it on the boat anyway.

After a while, after seeing it soaking in and maybe drying a little bit, I decided it didn’t look too bad. But it was dark and rainy outside, and I was only seeing it by the naked bulb in the garage, so maybe I’ll think it’s terrible again when I finally see it in full daylight.

It took a lot longer than I thought it would, brushing it on the wales. I had originally imagined that I’d be applying stain with a cloth, rubbing it on, rather than with a brush. But the instructions on the can were pretty clear about either using a natural bristle brush (which was itself not so easy to find) or spraying it on. So brush it was.

After a while I worked my way into a kind of groove, working about three inwale spacers worth at a time, first cutting under the inwale, then the broad side of the inwale facing inside the boat, then on top of the wales and spacers, then getting it between the spacers on the inside of the inwale and the bit of hull between with the stain left on the brush plus whatever had dripped down from doing the tops, then finally the gunwale.

Wales are stained

All said, I think it took maybe 2 hours. And now it’s really ready for painting.

Week 43: Final Paint Prep

At last, the sanding is finished!

Rain delay

We had a 3-day weekend, what with Monday being Indigenous Peoples Day, where Dawn and I had the day off but Tala didn’t (sorry, kid). We had a busy, busy Saturday so I didn’t get to any boat work until Sunday afternoon, whereupon it promptly started to rain. Just light sprinkling, nothing heavy, but certainly not good for an unpainted plywood boat. I covered her with plastic and waited for the rain to stop. It did stop, then started again. I finally just gave up for the day and put her back in the garage.

Sawing off the bow keel extension

With a bright, sunny day on Monday, I was back to work. First thing I did was saw off the extra lengths of the keel that were sticking out the bow and stern. They’ve been serving as quite useful handholds, but, alas, not permanently. So I finally, finally sawed ’em off.

Sawing off the extra keel and skeg at the stern

The extra bits sticking out the stern end included the skeg, which was harder to cut, given that it was a piece of oak that I’d had laying around and used rather than the dimensional pine or whatever the keel is. I gave up on the little Japanese pull saw and went with the bigger Spear & Jackson bad boy.

Keel and skeg rough cut

Both cuts produced rather rough looking parts, so I rasped and sanded them to a little more pleasing shape.

Keel and skeg finished smooth

The skeg again turned out to be quite a bit more of a challenge to shape and smooth, again because of the hard oak but also because I had to be careful to keep the rasp from marring the fiberglass seam just below it.

Keel bow point finished smooth

And with the keel in final form, I was finished with shaping and sanding. It was finally time to caulk.

Ready to caulk

I’m hoping that the marine adhesive sealant that I’m using is good enough. Jim Michalak seems rather adamant that thickened epoxy fillets are the way to go on these interior joints, but he compares the epoxy to auto body filler and RTV (silicone), whereas the PL stuff I’m using is polyether, whatever that is. But whatever it is, it’s a lot cheaper than epoxy, and a lot easier to apply since it comes in a tube like caulk.

Interior (almost) finished caulking

But, oh, friends, it’s not like caulk, in that it’s a whole helluva lot thicker. I spent two painful hours squeezing the caulking gun with both hands just to get the stuff to come out. Later research showed me that my little kitchen and bath caulking guns have a thrust ratio of like 6:1 or 8:1, even though they say Heavy Duty on them. Bigger, better, and more expensive guns go up to like 18:1 or 26:1. I’ll surely buy one of those if I ever had to use this stuff again.

Exterior caulk finished

In the end, I finished with the caulking. Whew.

Keel bow point caulked

This boat is ready to paint. At last!

Week 42: Sanding for the 4th Week in a Row

Spent 2 more hours sanding, including quite a bit of time with 100 grit on the outside hull sides. I cut into the fiberglass tape seams a little more, trying to smooth the transitions from wood to fiberglass. I’m hoping the seams will look better when painted.

And we’re up to 150 grit!

I also finished the outside sides to 150 grit. Feels really nice.

I’m hoping next weekend is the last weekend of sanding. Fingers crossed.