The first step in assembling the jig is to first assemble just about everything we shipped to you.
This includes, of course, the jig itself but it also may include FasBuild™ Components. Let's discuss them first:
Assembling the FasBuild™ Components:
First, a general overview about our "FasBuild™" components. As many of you know, ENVIBOATS offers quite a few options that can greatly speed up the process of building one of our boats. We call these our FasBuild components. If we can do some or all of the fabrication for you via our CNC equipment, then we can offer these components as FasBuild. For most of our boats, they include:
- Floors (the supports under the sole)
- Deck Components
We have NO desire to force you into purchasing these options so we engineered our jigs to allow you to construct them yourself if you so desire. Many of our current builders feel that the additional expense is well worth it when they examine the trade-off between making these componenents vs. buying them.
The advantages are clear enough. If you put them into the jig, they are already there when you flip her. Imagine not having to hand fit a single bulkhead.
We estimate that the entire FastBuild package on one of our boats will save the builder about 140 man-days of construction.
Ok, now you know a bit about the ENVIBOATS FasBuild components.
So the question at hand is: "How do we assemble them and incorporate them into our build?"
We believe that the very best place to assemble your FastBuild components happens to be your newly constructed and perfectly level base. Start by organizing all the parts. Each part from ENVIBOATS is engraved with an ID number. Typically Jig Stations are numbered starting at the transom and bulkheads / floors are lettered also starting aft.
Key point: We try to make the assembly process as easy as possible by providing CNC cut alignment holes into which you insert lengths cut from standard dowels. (Typically 1/2" dowels) The purpose of the dowels is not to "lock" the pieces together during the gluing process but more of an alignment and assembly guide. If the holes don't line up, somebody did something wrong and we should stop, talk, and sort it out.
Once you sort and identify the parts that form a FasBuild™ component, arrange them on the base like you will be gluing them together. This is called "dry-fitting".
Key point: Protect the base with a sheet of plastic. The last thing you want to do is to glue the FasBuild™ components down to the base.
To clamp the parts while gluing, you will drive screws completely through them directly into the deck of your base. Use drywall screws and fender washers in the same way you will clamp your planks when you get to that point in your build. Some of the FasBuild™ components will require significantly longer screws, however. Once you have dry-fit the parts and understand their orientation, drive a few screws in them before you mix the glue. The "problem" you are trying to avoid is that when the parts have epoxy on them, they tend to slide around as you are clamping. The dowels definitely help you avoid this situation but the few screws that you just drove when you dry-fitted the parts will ensure that this does not happen.
Let's do some gluing:
- Unscrew the parts and organize them on the base in the order that you intend to apply glue.
- Apply epoxy glue to the surfaces to be joined using your notched spreader. The glue should be thickened to roughly the consistency of peanut butter.
- Stack the parts.
- Insert the dowels.
- Drive the screws back into the exact same holes that were prepared during the dry-fit process.
- Drive enough new screws to properly clamp the component.
- Clean as much glue "squeeze-out" as feasible prior to the epoxy hardening.
Key point: Extra care should be taken to ensure that the stringers are assembled as rights and lefts. The parts comprising the stringers are identical in their right / left versions. What makes them "handed" is the order and orientation by which they are assembled.
Key point: Let's discuss FasBuild transoms. On boats where the transom is bigger than a sheet of plywood, the transom is usually assembled from four layers. The forward two layers are assembled into the forward "half" and likewise for the aft "half". Assemble the halves individually but do NOT put all both halves together at this time.
Additional instructions will describe that process.
Now on to the next part where the fun begins
Assembling the Individual Jig Stations:
Very soon you will see the lines of your boat firsthand.
Once all the frames of your jig are assembled as well as any FasBuild components, you are ready to setup your jig.
Your base should be fully laid out at this time.
2x2s, cut to the length of the bottom of each jig station should be screwed to the base, centered side-to-side, with the forward edge of the 2x2 just touching a station layout line. Starting at the furthest aft station, place the station against the forward side of the 2x2. Align the station centerline that is engraved into the bottom piece of the station with the center layout line on the base and screw it into the 2x2. It is probably easier to get some quick help from an assistant for this first station. Once it is in place, you can use the "third hands" that are supplied with your jig to simplify the process of placing the next stations.
Key point: Remember, to flip your boat, these screws attaching the jig to the base must be removed. It would be a good idea to use washers under these screws so that you don't bury them in the wood making them almost impossible to find later. Also, if your boat is small, it is probably VERY DIFFICULT to get underneath the boat after it is planked. Therefore, all screws attaching the jig stations to the 2x2s should be driven by reaching in from the sides. That way you KNOW you can reach them later.
Set a jig station in place and drop a third hand between it and the previous station to to hold the new station temporarily. Screw it in place and move onto the next station. When this process is complete, get some help and set the Keel and Stem Pattern in place. The corresponding notches are designed to have sufficient clearance for the components to simply slip together.
To tie it all together, simply drive drywall screws at 45 degree angles through the joints between the stations and the Keel and Stem Pattern.
If you purchased any FasBuild structural components, CNC-cut stringers or keel, get some help and set them in their respective notches in the jig. They need to be attached via any means that permits removal of the jig after the "Big Flip". Typically this means aluminum or steel "L" brackets placed between the stations and the structural component.
Now it is time to move on the the building laminated structures...