New Boat Build Project - (Totally Rebuilding An Older Boat)

[jamesmusslewhite]

I have owned six boats over the 7 years we have lived here in the Surigao. One of the advantages of living here in the Surigao City area is boating, with great fishing and so many small islands around here to explore a boat is a sound investment. That and it seems my wife has family in almost every island around here so having a good boat has benefit.

 

This was a 34 footer  I purchased back in 2009 which we took over to our small beach lot in Tagbirayan, Dinagat Island.

 

 

I found it to be a bit uncomfortable as it had a rather narrow profile at the bottom which made it difficult for someone my size to move about on the boat and a bit too rocky for my liking. It was a good boat for fishing but the plywood bottom also was just too flimsy for the shallow waters here due to large rocks and coral below the water line as tides lowered. This can be a bit unnerving when boating in the shallows at night when you could not spot big rocks before being able to avoid them. Sometimes I do not know how we could not have cracked the hull or sprang a leak on a few occasions. Seven years living here I have seem more than a few boats sink while bouncing off the rocks and coral in these waters around these little islands around here. The plywood bottom also meant it rot rather quickly and was just not stable enough for me to trust selling the boat to someone else. It is also hard to insure the actual quality of the marine plywood when you purchase the sheets and can be using a slightly inferior quality without known, that is until it dry rots or the laminated layers begin to separate. So we eventually just stripped it down and burnt the wood after retrieving the brass nails and aluminum rudders and propeller shafts.

 

I tried to find a wooden slab that was at least 32 foot long with the width I wanted but was unsuccessful finding a slab of wood that size, that did not cost more than a new motorcycle to get delivered over to Dinagat Island. This was when I decided to try to find a used boat with a solid wooden hull board and then strip it down to the hull board and then reconstruct the boat to fit my own needs.

[jamesmusslewhite]

After about a couple of years I came across an old calamari style fishing boat that another expat had purchased as a hobby but left it exposed where it suffered carpenter ant damage to parts of the plywood skin. He had decided against trying to restore it, where it sat upside down on two wooden saw horses where it became ‘yard art’.

 

I was once asked what exactly is a calamari boat? So I will add the following photo of one from one of the island across from Surigao city. It is a boat which is fitted with bamboo riggings and night lamps which the locals here use to catch calamari at night. They tend to be designed for rough water which means they tend to have higher sides as well as holding compartments than do the standard traditional Filipino boats. 

 

 I purchased the boat for only 10,000php which was more than a good price as all I really wanted was the wooden hull board. If I were able to find such a large piece of wood I would have spent many times that amount just getting it to Surigao city, then I would still have to get it to Dinagat Island were more would have been spent carving and shaving the 32 foot x 1 foot x 3 foot plank down to the desired shape.

 

 

in this Face book video you can get an idea how this old calamari was constructed and what it looked like before we moved the old beast. Sorry you may have to have a Facebook account to view it.

https://www.facebook.../3266508501428/

o give everyone a visual perspective of just how big a 34 foot boat really is and just how difficult it is to transport one that size, this is it loaded on the back of a dump truck. It also took a dozen men to load it and then again to also unload it off the truck.

 

 

The boat received some minor damage to the upper hull while it was being hoisted onto the top of a dump truck and transported down to a local friend’s river property. But it was still more than sea worthy enough to be towed over to Canbunga-an, Dinagit Island where we would quickly start tearing down the boat down to the the 32 foot single piece hull board. This piece of plank was carved out of a 32' x 3' x 8 '' piece of hardwood which is now very difficult and very expensive to purchase and transport up to Surigao City and then over to Dinagat Island. 

 

these two photos were taken as we were removing the deck wood and it may help those interested to see how the inner hull frame is designed for a boat with high sides. The new design we are using has lower sides so will only need one rib support running the length of the sides instead of two as is used on the original calamari design. We will not be using it in rough nighttime weather conditions as those that calamari fishermen must face so the higher sides are really not necessary.

 

 

 

Well you have to crack some eggs to make an omelet. Once the boat was dismantled we had the 32 foot hull board transported over to our small beach lot in Tagbirayan, Dinagat Island where it was placed on saw horses for the next two years. Several months ago we had it moved over to our farm and started designing just how we were going to do the reconstruction. For our design we need a boat that is good in the shallows but can still be used for ocean net fishing. A boat that can be used to run goods and supplies around the island as well as trips between Dinagat Island and Surigao City when needed to get building materials and to use to get to the lobster huts, fish traps and for transferring and transporting lobster and fingerlings.

[jamesmusslewhite]

We placed the hull board behind a shed and under the mango trees so we could work in the shade while we were working on the boat. The following photos will show the project as it has progressed over the last couple of months. The boat is being build the old traditional way which I am sure many will find interesting. The rib frame for the hull is chiseled and carved and 'fit and slot' together and epoxied. Much of the wood was actually hand cut from a tree we fell on the property using a hired chain-sawer. The wood was then cut and split using a jigsaw and chisels. If you have questions I will be glad to answer them and I will try to show enough angle shots and close ups to help viewers see how each process is done. and will show the project up to date. Then later I will be adding new photos and descriptions as the project progresses until completed and in the water.

 

First we laid the hull board up off the ground behind our tool shed on the farm and cut all the pieces that will be used as ribs for the hull. We then marked and chiseled out the slots were the ribs will be inserted into the hull board. As we inserted the ribs they were epoxied into place. The ribs are slightly recessed and the hull was mitered using chisels so that when the plywood skin is add it will be flush with the side of the hub board.

 

Then the first top rail of the hull frame was laid out and rectangular slots were chiseled so it can be taped over the top of each rib and epoxied. The top rails are one continuous piece of wood which has also been mitered on the bottom of the outer side so that when the plywood skin is added it will be flush as it is epoxied and nailed to the hull frame. Also the top of each rib was notched so as the top rail was tapped in place to would rest at the proper height. (this will be shown in other photos posted later).

 

 

[jamesmusslewhite]

This photo is the second top rail being tapped in place. The photo also shows that when doing this to start in the middle ribs first, then have someone gently pull the top board inward so it will relieve stress on the top board and make the task much easier than it would be by trying to start at one end and trying to work your way to the other end. The top board is then then tied to the bow and stern boards until the epoxy has properly dried. Then notches will be later cut into both sides of the bow and stern boards where the top rails will then be pulled up and epoxied and tied until it has properly dried. This will give the distinctive traditional curve shape at both the bow and stern of the boat. This will be seen in later photos.

 

It is not hard to do, one only needs to be patient and not try to over muscle it as spiting the rail board is not something you want to happen as 36 foot strips of wood are hard to come by and taking the rail off and having to scrape off all the epoxy on the ribs is rather counter productive. Even my niece could do it so it is a matter of brains over brawn and just being patient and gentle. My brother-in-law simply instructs us as he is tapping the board in place so the task is simple to do.

 

Top rail is done for now and simply tied off to hold everything in place. Next step will be adding the middle hull frame rail down each side of the boat.

[jamesmusslewhite]

Next will be to flush cut the top of the ribs with the top rail and apply some more epoxy just for additional strength and peace of mind.

 

 

My wife who makes a lovely assistant, shows just how roomy this old beast is for a 5 foot tall Filipina will be when she is finally completed.

 

 

Now I'm just under 6 foot and weigh 235 lbs so you can see the size relationship. And shows it is rummy enough for even my fat ass.

 

Now comes the task of adding the middle hull frame rail down each side of the boat which is to help strengthen the frame and allow more surface to epoxy and nail the plywood outer sink for the hull of the boat. the length of board is carefully measured and notches are chiseled for each of the ribs. Each notch is cut to where it will be flush with the outer side if the rib frame once epoxied and nailed into place. Unlike the top rail which is a single piece of wood, the middle rail is actually three pieces of wood. This is done by applying epoxy to the notches and starting at the end and working towards the middle and nailed at each rib to firmly hold it in place. There is a pencil mark where each rib was pre-measured which allows the boards to remain straight as it is worked along the length of the boat. Where two ends of the middle side rail meet, they are epoxied and nailed to the rib or firmly held in place with a c-clamp until it has properly dried. 

 

 

When dried it is time to make the notches in the bow and stern boards and make the curves

[jamesmusslewhite]

The bow and stern boards are then notched out with a chisel so the top rails can finally be pulled up to make them curve. This is more for practicality that for looks as it actually helps when cutting through waves when the sea gets rough which can happen at a drop of a hat when out in open water. Rain bands are common and what was a calm sunny day can quickly become windy, wet and nasty with serious chopping waves. That little curve can make all the difference of climbing a wave or having the bow or stern pushed down by the force as it is like a curved tip of a slicing blade. 

 

Bow board

 

The bow board now has the beginning shape carved.

 

 

 

 

 

The Stern board

 

Stern board after top rails, middle rails, pipe and propeller shaft installed. The top of the stern board has the beginning shape carved. 

 

Now need to install propeller pipe. shaft and propeller, motor mounts and install the motor.

[jamesmusslewhite]

Now installing the propeller pipe. shaft and propeller, motor mounts and motor on this project is pretty easy as the hull board was already carved and set up already. First the pipe must be installed and epoxied in. It should be noted that these tasks be completed before you put on the plywood skin so you will have room to work, if not that you will wish that you had due to the tight space. First the pipe that will be used for the propeller shaft.

 

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This needs to be done first so you can adjust the motor location for the mounts to the shaft length. The motor can be easily adjusted were as the shaft and propeller does not adjust well to the motor location. Now to locate the motor and mark were the motor mounts will be located

 

 

Then you only need to mount the motor and the universal fitting to the end of the shaft. I can assume everyone now understands why it is best to do this before epoxying and nailing the plywood sides.

 

now at this point it is time to add the boards on top of the top rail were the bamboo outriggers will be. This boat will use three outriggers which will hold and support the floating bamboo wings on both sides of the boat. I did not include the following information earlier because it could have been confusing. When we designed the boat we figured how many and where each out rigger would be located. Since we will be using 3 out riggers we properly spaced 3 extra large ribs to add as proper support for these 3 outriggers. These boards that will be added to the top rail will support the weight and act a place to secure the outriggers to the deck of the boat.

[jamesmusslewhite]

Now we add the support board for the three outriggers to the top of the side rails.

 

more to add later as the project progresses.

[jamesmusslewhite]

Well yesterday we took a trip to the city and purchased the plywood for the hull skin. The boat is 33 foot 9 inches in length so we only needed 5 sheets. The shop where we went actually carries 1/4 inch #1 grade Santa Rosa marine plywood @ 700php per sheet 

 

I also did some pricing on boat motors, specifically 20HP diesel engines I did find one that interest me which was a 'Yama' brand made in China. The price was 19,000php and they will allow me to put one on a lay-a-way plan. I have to go out of country by the 15th of March to do the Visa run so once I am back I can put down a deposit and than pay it off over a few months. I was told by some of the locals here that the 'Yama' brand engines have a good reputation for being both an affordable and a reliable motor, and that repair parts are available in this area. I have seen 'Yama' pumps and generators being sold both here and in Cebu. Have any of you guys actually heard of the brand and perhaps have some dependable information on these engines? Yes I know Kabota, Yamaha, and Hondas are vastly superior brands but their cost also reflects this which for now puts them well out of my price range

[jamesmusslewhite]

I was asked once, "what to look for when trying to purchase a used boat?"

 

I have bought a few here over the years and I learned the hard-way on my first purchase. It was a 26 footer that I purchased from a Surigao expat. I was told it was a sound boat with all the parts (no motor included) which was being stored at a friends house. I went over and looked at the boat. This was in early 2009 and the price asked was 6,000php. I paid the man did the paperwork and then went to get the boat. Then I found out the floorboards were missing, the bamboo outriggers and bamboo wing floaters he showed me actually belonged to the local Filipino friend who was watching the boat, and that the expat had actually sold the rudder to the boat earlier to his Filipino friend. When I informed the expat of the discrepancies he merely shrugged it off and implied that he did not know and he had already spent the money.. Two options were left to me at that point, option 'A' beat the little weasel, or option 'B' just chalk-up the loss as a learning experience. I was surprised that I actually picked option 'B' but I had to spend almost another 6,000php to purchase all the items that were missing and get it over to Dinagat Island were I discovered the plywood bottom had dry rot having been sitting upside down in the full sun. So 12,000php for something fit only for burning, and at the time 15,000 would have purchased a new boat of that size (without motor), or a good used boat of that size with a motor included. Later I talked to another expat who had come to the Surigao City to visit his girlfriend and discovered that the boat actually belonged to him and that the expat sold they boat without even asking him first.

 

Lessons learned?

A. Trust nobody on just their word.

B. See the boat first with all parts accounted for, and have these parts listed in writing and signed by the seller before payment.

C. Check around with the locals and find out what the reasonable expected price for a new or used boat.

D. The motor - American or Japanese internal parts because Chinese motors with Chinese internal parts are crap. Some Chinese motors do have Jap parts as they assembly-line for Japanese companies. Go to the local dealers who sell boat motors and ask "Chinese components?" or ''Japanese components?" and they will both know and tell you. That little fact I learned a couple of years back when I was going to all the shops selling motors here, and it is important to ask. Same identical motor can be found in different shops and some came off the assembly-line with Chinese components and the other with Japanese components. Trust me the dealer knows, and if he acts like he doesn't then he is either an idiot or a shyster so do yourself a favor and just walk out and go to another shop.  

E. Look how the hull frame is put together. As you see in my photos the horizontal board running down the length of the hull frame on the inside. This should be thicker than the ribs and notched the fit over the ribs. Some boat builders will cut these only to fit between the ribs which give not real strength to the sides of the boat. Trust me, if they did that than they probably also cut every corner possible when building the boat. Walk away, you will find a better built boat for the same price. They can paint it where it looks really nice and hide all the flaws, but a well built fame is easy to spot. 

F. Look at the seams were the plywood comes together and joins very closely. Sometimes they will try to wood putty cracks, splinters and seems, but like with bondo on a car, if you look closely you can see where it shows under the new paint because there will be a discoloring under the paint.

G. Do not be in a big hurry to buy a boat. Lewis's Law, "A better deal always comes, after you have already made the purchase." Man, it that true when looking for boats here in the Philippines. Due diligence can serve you well in this case of finding a quality used boat. Locals will try to give you the 'Long-nose Tax' just write down a more-than-fair offer with your cell phone number if you think they are trying to over-price you on a boat. They will look at that number you quoted on that piece of paper and odds are they will call you and settle on your price. If not, than don't sweat it because there is always another boat for sale here in the Philippines.

 

these are the main thing I can think of right now, but I am sure others can add to that list of "what to look out for."

 

 

 

I will be adding more photoes shortly and will continue to do so until the project is complete and the boat is in the water. :wave:

Edited October 11, 2015 by jamesmusslewhite