July 26th, 2015. 8 hours of work got us to this point. Most of this
boat was assembled by me a couple of hours at a time. The main sheets and
ribs were made and cut out by the boys on Sunday night. 5 days later the
boat took this form. The sheet of card board is 15 ' 2" by 6'
5" it's one and a half times the thickness of regular cardboard.
No wood or screws remain in this boat. It's all cardboard, glue and paint.
Click on a picture for a larger view.
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You need pressure and weight for a strong joint
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Discarded marble counter tops are great weights
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Ribs and 3" wide flaps make good joints
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Temporay supports to hold the boat in shape while glueing
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I used old fence boards and the deck screwes for clamping
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these deck screws are the best 2 threads pull joint tight get square headed instead of phillips to keep them from stripping out
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Keep weight on all the glueing surfaces for 20 minutes.
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Anything works for weight. Flat surfaces are best
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These are 3" jig boards that match the ribs in lenght and width plus they are 3" wide to mark the flaps.
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All the tools you need to make a good boat not showing the weights
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It's neater if you can squeeze glue out of a bottle. On big flat surfaces I just pour it from the bottle. besure to thin the glue
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This little red tool is handy for making cuts.
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The square head screws and cordless drill and the 2 chipboards on each side of the cardboard make the best clamping system I have found.
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This stack was 4 feet tall... Many years of fun!
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Added another rib in the front and back section
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Harbor Freight will have these on sale for about a buck a piece. Buy 25 at a time. Very handy
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Glueing on the top deck will cut holes out in a few.
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Besure to remember where the ribs are I measured from the back of the boat.
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Weight slides down hill so added some screws to hold the weights from sliding down. This is a closed in part and no chipboard could be used on this.
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Placing it on the side and first glueing the side that is on the bottom added weights then did the same on the upper side.
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Need lots of weights. Landscaping step stones will work as well.
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Flaps must over lap the joints
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I put down 4 sheets of card board as a work surface and use them for the boat launch at the lake and to cover the card board for the return burn pile.
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Don't leave the weight on over night. It could mash your boat or cause it to sag.
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