Dory Progress - stem, transom and rails

Time to get going on fitting out the hull. 

Mahogany will do nicely, durable and straight grained for the most part, and easy to work

 1.5" board for transom, stem and other trim

 To be laminated for the necessary stem width

 Transom fitted and epoxied into place

 Stem in place

 Rails dry fitted

 Helper as outfeed table (and infeed immediately preceeding)

 Railstock ripped, to be dimensioned

 Finishing rails

 Rails just 1" short!

 Rail extensions spliced on

 Lots of wax paper during clamp up to keep squeeze out from gluing parts together

 Rails fitted, to be beveled

Ends cut and beveled

 Rails ready to fit, after epoxy sealing backsides and lower edge

Next up is inner rails, seats and centerboard trunk trim

Form progress and stem bending, March 14/05

Friday the 13th has come and gone, today it was time to get back on the project. Stem form was ready, and the stock was soaking for 3 days. Fired up the propane burner for stream, hit the blank with 190degree stream for 90 minutes and it bent up beautifully. Dressed the white oak backbone, and set the fasteners in the form so its ready for the top to be covered, and faired overall. Last steps are to set the bands when the stems are set on the form, and the gunwale backers will need to be steamed to shape and attached. 

Plastic tube for soaking stem stock with high-tech duct tape to hold stock down into water

3 days of soaking air dried wood, ready for bending. 

Form ready, typical system has wood tabs with a dowel , and a wedge driven down to hold. Works great, but c clamps offer as much or more clamping pressure, and are quick. 

Steel backing strap prevents tension failures during bending.

Bent and clamped, to set for a few weeks before removal and halving. 

Stem shape

Steam, lots of steam. 

Heading to 200degrees

With some time to spare during heating, took care of part of another project and milled up ash gunwale stock for a project boat coming in soon.  

Hold down bolts set into form for strongback, next to close it in and fair. 

Working in the shadow of the original provides lots of inspiration as the end is in sight, and so close 

to a new build.

Awesome quarter sawn white oak strongback, thanks to Rob's eye while at a sawyers. At 2.5"x3"x14 feet, is solid and perfect. 

Dressed on the planer, the fleck from quarter sawing is evident. 

Hit with Tung Oil, it looks great. 

Next, closing and fairing, and steel straps, followed by gunwale backers. 

Skid plates

Usually seen on royalex and river canoes, these dont slow you down noticeably and for glass canoes such as this one, with no bang strip, there's nothing to protect the gelcoat stem. 

A few pictures on how to put them on, once the felt is impregnated they are near bulletproof. 

And now for something completely different - a custom beach cruiser build

Yup, like most everyone we love a ride on a kool bicycle. Gone for now are the loud motorcycles, and flat out mountain bikes for scaring yourself off road. These days, much like paddling, we're content to slow down and enjoy the ride. My first foray into the world of the ultra comfortable, sprung saddle and fat tired bike was this green Haro Railer XS. Not a cheap bike, all aluminum and tig welded, with gold anodized rims, stem and crank you either love it or hate it. Lots of people give it a thumbs up. 

Patterned off of the balloon tired bikes of the 30s, 40s and 50s, the frame is styled similarly but the components are a mix of bmx, dirt jumper, mountain bike and cruiser. 

Haro made a few versions, this one unfortuately besides being accented in pink, is a single speed, and that just doesnt work for any kind of hills although its fine at the beach.

Styling runs all over with these, from mild to wild. An internet search for 'custom beach cruiser' will display just how far and in how many directions they can be built.

Key to moving them around are the newer internal hubs from companies like Shimano. Improvements on the old English Sturmey Archers, they are updated and shift flawlessly. The Railer has the one on the right, with a drum/band brake. Not as confidence inspiring, as its the only brake you tend to think of contingencies on fast downhills when getting ready to stop. The model on the left has the more robust coaster brake. 

Shifting gear for the Nexus hubs, 3 position twist grip and actuator

A great looking retro styled model from Nirve

Another awesome variation

Enter our subject bike, found on Kijiji for a song. Aluminum framed, quality build from long time Canadian company Norco, it will provide frame, wheels, 3spd hub and forks. 

Not a real looker, but it does have some nice inserts we will use later for the theme we are going for. PeeWee Herman bars will have to go...

Wheels - can'd decide if we will go back with whitewalls or some other combination of blackwall or stripe. 

Knocked down in 1/ 2 hour, we have plans for the plain paint finish

Headbadge and decals have to go, along with all bearing cups and races before the blaster

Off to the next step, bye bye green. Wonder whoever thought pink stickers would look good on forest green.

Powdercoated inserts

Forks, also flat black and powdercoated

Even did the stem to the insertion point. Powdercoating adds thickness when it bakes on to form a film, so threads must be plugged and/or parts protected where clearances would be lost, such as the quill stem inserted into the fork tube.

Gloss Burgundy frame, flash does not display true colour which is darker

Closer to true colour, no flash

Front end, inserts, and bars will all be flat black

Time for reassembly. Stay tuned for the theme, as it gets ready for presentation to its new owner

Headset races back in 

Headset assembled, new vbrakes on. Candy red low rise bars on order along with new whitewalls. Next up are wheels, then the crank , chain seat and lets go riding....

Frame inserts need to be put back in and custom graphics applied

Progress! ignore the fingerprints on the flat black, assembly makes greasy hands. 

Big difference from the original, again below for contrast. 

Progress! Red anodized downhill bars arrived, along with new whitewalls

Nice and wide, and moderate rise. Way better than '50s PeeWee Herman pullbacks

Couldnt resist a quick mock up with the old wheels and tires

Now on to cranks, wheels, seat and controls and to wait for spring...

Had to put a coloured chain on it - cranks shined up, final assembly not far off.

Almost done, black post and clamp and cruiser seat, ready for graphics and shifter/cable assembly and final tuning

Custom all the way, will be a great summer cruiser and there wont be another one like it. On to its new owner soon, once the vinyl graphics are done.

Finished, just waiting for the graphics. 

Mechanically completed and tuned, ready to ride.

Still cold out, but feels like spring. Too much salt on the roads for a run though...

Long way from the pile of parts we started with, and now a one of a kind cruiser. Spring cant come fast enough, so we can move this on to its unsuspecting new owner. 

Looking good in the sun

Next to my factory stock Haro cruiser. I like my build better....