NEW
WOODWORK BEADING AND CAPPING IN SCM HURLEY 22 1115 VIXEN
BY
KEVIN MITCHELL BOAT OWNER AND PROPRIETOR OF HIS SMALL JOINERY BUSINESS
KNOWN AS WOODWORX
Kevin's
boat Vixen is currently kept in Torquay she was formerly known as
Sundowner when previously owned and used as a sailing school boat
at Rock in Cornwall. To provide a measure of privacy at that time
a small bi fold door had been fitted to an altered main bulkhead.
When I bought the boat I felt there was no longer a need for this
and it also made the interior look rather cramped and so proposed
to return the opening to the original graceful broad keyhole shape.
In my mind I also planned to fit a roller blind in place of the door.
Once the
boat was in my posession I spent some time making a list of work to
do inside and started by removing everything unwanted and preparing
the bulkhead to receive a surface covering of thin 5mm Meranti veneered
marine ply from Robbins of Bristol. I made patterns from cardboard
to ensure a good fit, port and starboard and also on the small divide
between the galley and the port hand quarter berth. Both these original
laminated surfaces had been damaged over time with scratches and old
screw holes. Once I had cut the plywood on my small band saw at home
I offered them up in place to make fine adjustments for a perfect
fit then returned home to begin the process of staining and varnishing.
I used two coats of Mid Oak stain varnish followed by five coats of
clear gloss.
Having worked
as a shopfitter in the past I am well aware of various types of glue
especially when fixing plywood to a laminate. For this it is a good
idea to score the laminate with a series of diagonal lines one way
then repeat the process in the opposite direction, I used one corner
of the blade of a sharp chisel. The scored laminate then provides
a good key for the glue. I chose a relatively cheap modern impact
type which boasted being suitable for marine environments and had
around ten minutes to be sure my wood was properly in place. However,
full strength would not be achieved for twenty four hours so I therefore
made use of a number of different types of cramps and long bars of
wood with soft pads on placed between the ply and suitable jutting
out other parts of the boat.
Once the
glue had set and all the cramps removed I prepared the surface of
the cut out keyhole shape to accept a solid wood surround, which I
was going to bend myself to fit. Now the traditional method of bending
wood is to steam it but I had researched alternative methods and found
an Italian company who had skilfully worked out that if the cellular
structure of certain timbers is suitable a baulk of timber can be
compressed both over it's length and breadth under great mechanical
pressure and may be stored indefinitely in dry conditions until required.
The British agents for this treated timber known as Bendywood are
called The Angle Ring Company and are based at Tipton, in the West
Midlands. When someone wants to use it, the timber can be sawn, planed
and spindle moulded dry then it is placed on blocks of wood on sheets
of wet cardboard within a wrapping of polythene. The whole parcel
is folded neatly and tied securely and left for a week for the timber
to absorb the moisture, thereby expanding the cellular structure again.
Whilst this
was happening for me I used my original cardboard former inner radii
and measured the distance they would be apart to provide the full
bulkhead shape. I drew this onto a half sheet of ¾ inch chipboard
(half being across not down it's length) and then proceeded to screw
blocks of wood to the outside of my line allowing for the thickness
of my new beading which I had had rebated out so as to go over the
edge of the bulkhead cut out. An additional piece of 18mm plywood
had originally been fitted by the previous owner to the forward facing
side of the bulkhead which I had left to add general strength so my
rebated bead was done to a width of 36 mm plus 5mm new ply plus 1
½ mm extra so it would not to be too tight. The width of my
bead allows it to project beyond both wood surfaces by around 15mm
on each side which provides a grip edge but means that the overall
width is 72 1/2mm which is a formidable width to bend for anyone by
any method.
Once all
the blocks were in place I cut additional ones which would be placed
inside the beading as it was being bent around the radius under pressure
from various types of cramps but mostly sash type. The day came to
do the bending and the process has to be achieved fairly quickly and
preferably in dampish or at least humid conditions. There are no photographs
of this as I needed both hands to do the job! Once the timber was
in place and well cramped down it was left for a further week before
removal and the results are as you see them, two handed pieces.
The capping
for what I shall refer to as the 'galley divide' was nothing like
the main bulkhead in dimension or rebate but this again was done using
a former in a similar way. I also cut back the original divide on
the outer radius to form the inverted part of a handle and when the
bead was in place it provides a very useful hand hold.
On my first
visit to Vixen with the bent timber I realised they did not fit completely
to the bulkhead shape but I knew all was not lost and had planned
for this by hiring a brand new 'trench prop' like an acro which builders
use for holding a lintel in place whilst knocking down a supporting
wall, my prop was shorter and new because builders generally get this
type of equipment pretty dirty. In my photo you will see this as a
bright yellow tubular bar one end of which cranks in and out on a
thread and it enabled me to work gradually up and around my bead putting
in a pair of 2 inch x 10 screws side by side every 200mm. All went
well and no glue has been used at all. Before the screws were put
in I pre drilled each hole with a special bit to provide a recessed
short hole at the outer end where I knocked in wooden plugs I had
cut earlier (these are glued in). I also had to scarph in a header
piece of timber which incidentally is Beech to match the Bendywood,
a timber not ordinarily associated with boats but whose cellular structure
is one of the better types for this process and since it is varnished
and not exposed to the weather there should be no future problems.
My next
photos show the raw unfinished beading with tiny plug ends above the
surface. I then left that particular job for another week to allow
things to dry and to settle.
With a sharp
chisel I pared off each wooden plug and sanded the whole surface prior
to a long process of stain and varnish with many coats and the result
is as you see it, quite an achievement but I set out to do this and
it certainly was a challenge for my woodworking skills. From the arrival
of a rather banana shaped piece of timber just over two metres long
x 100mm x 50mm I had marked out and cut the timber myself then had
Bovey Joiners machine each piece with the spindle moulder to my specifications,
bought the additional header piece from them as untreated because
that piece would not require bending and completed the whole subsequent
processes it had taken three months of care, precision and dedication.
Just to
finish this technical piece of work I have a couple of photos which
show the newly covered forward facing side of the main bulkhead complete
with the blind.
Kevin Mitchell
SCM H22 No 1115 Vixen, Torquay
PICTURES
OF THE PROJECT
Click on an image
to enlarge
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1.
Original layout looking aft
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2.
Old bulkhead and my son Chris
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3.
Original shape recut
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4.
New plywood face
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5.
Starboard
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6.
Port
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7.
Capping prior to bending
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8.
Capping for galley divider
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9.
Capping bent
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10.
Handed cappings
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11.
Starboard gap
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12.
Added pressure plus screws
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13.
Both sides in
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14.
Looking aft - also new ply by hatch
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15.
Nearly done plus galley divide
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16.
View into the galley with the main bulkhead capping to the right |
17.
All stained and varnished - the bulkhead from aft looking forward |
18.
From the stern looking forward with the blue blind fully extended
down |
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19.
Forrard cabin with blind down looking aft. |
20.
The carpeted bulkhead |
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