The Perfect Shop for the Cygnus Duo
The concept drawings for this vessel began in 2003 with working drawings started in 2006, and completed in 2007. However, this was only the beginning as much needed to be accomplished before building could begin.
Heavy load bearing shelving needed to be made to hold the planks that would be milled and stickered for curing. Using ancient joinery techniques, as used in York England and Rothenberg Germany, the shelves were made from wood with the joint strength increasing with the load, the stress being transferred to the wall or vertical member.
Meanwhile, the milling of 20’ planks require a 20’ in run and a 20’ out run from the Band saw to be used. As the wood shop was too small for this requirement, the benches, constructed for this task, were positioned to allow the out run of the planks to exit through a side door.
Finding a 40′ Building
The actual boat construction would require building a boat shop at least 40’ in length. The site had 3 existing pole buildings of various heights and dimensions, all in a line and connected together. At 41’ it was long enough however the poles did not line up, the buildings were severely out of square, and the floor grade dropped 12” in length and an additional 4” side to side at the low end. Even so, by adding poles, compacting the floor, adding footings, squaring two walls to each other, and using glulam’s to cantilever over the out of square walls it was made to work.
A loft and a 12X12 pitch roof completed the shop to allow space for the electrical parts that were stored in the pole buildings prior to the remodel. This project took over two years to complete. Once the boat shop was completed work on the catamaran improved a great deal.
Ready to Build the Boat
The stems and keel pieces had been shaped and the inner keels laminated. Section forms were attached to the inner keel and stringers attached to them to give the proper twist and fair line for laminating the ribs. The forms are attached to a beam notched into each form that keeps the hull level and straight and plumb on the vertical line.
Planking is started with the hull upside-down, and stopped when at 6’ above the determined water line measured at the center beam line (as pre-determined). 3 layers of 12 oz. glass are laminated to the planking at this time, wrapping completely around the bottom and the inner keel. The outer keel is epoxied and bolted on and the wear strip of oak attached. The hull is then turned over, lower bulkheads installed and the lower inside hull glassed. It is quite involved and there are many parts and processes. I will update this blog with progress on Cygnus Duo and add pictures to show the different stages.