Biscayne 22 Build - biscayne22

Biscayne 22 Construction

Stack of Mahogany
The first real day of work and expense began with sorting out lumber for the build.

Springing a batten
Springing a batten

Getting an exact duplicate
Flip the Masonite and use the router to make the other side of the same frame.

Mirroring using Masonite
I was able to mirror the frame bottom by making one side and duplicating it in Masonite.

Frame Parts
Here all all the parts of the framing in one spot. Most are still double stick taped together.

My First completed frame
This one took a long time to check and cross check and second guess..

The Second frame went a lot fast

Making two at once..
I gusseted the frame halves while they were still stuck together. Then I separated them - so they are mirrored too

Full Set
Here are all 8 frames stacked in order - once you get a system of assembly working, it goes fast.

All my small clamps
Here are all my "C" clamps laminating the 3 layers of the stem.

Here is my scarf jig.
Here is my scarf jig. I've started the motor stringers.

Stem fitting
I couldn't wait - so while fitting the forward frames, I did a test setup with the stem.

Sheer Notches
Here are the sheer clamp and deck clamp notches being precut. They will need custom fitting when installing the parts.

Pre-sealing the frames
I'm pre-sealing the frames with thin epoxy. - Probably would not have done this in hindsight. Easier to do later.

Completed Transom
Completed Transom

Fitting frame #8 to Stem
Fitting frame #8 to Stem and getting ready for final attachment.

Nice Shot with the door open

39 Clamps -
Holding the second layer of the keel while the epoxy sets. I could have used a few more..

Milestone Reached.
Milestone Reached. All frames, stem and first layer of keel secured permanently!

Closeup of Left Side

Here are the Chines in place
It really looks more like a boat now

Profile of Chine installed

The sheer clamps are laminated.
Here is the second layer after clamping. 57 clamps on this side!

Started with sides
They are a lot simpler in batten placement.

All of the side battens in place
The bottom ones will be tougher because placement is not as simple as the sides.

Topsides battens completed
After a few weeks of spring slowdown, I was finally able to complete the battens on both sides.

Notch Jig
Here is the jig I made to work on the many notches to be cut for battens

Faired Bow
Plywood stem was a lot of work to cut down..

Completed fairing front view.

Router Jig for cutting limbers.
1/2" core box bit.

Closeup of Limbers cut in bottom

Large View of Completed framing.

Closeup of bottom.

Inside the frames.
Inside the frames.

Finished transom
Estimated holes for exhaust. Turned out pretty close.

Beginning of Bottom planking

First layer on the transom

Fairing of the frame payed off
This is pretty good to me. I need to smooth out a few spots and get ready for the second layer.

First layer planking continued
Working my way forward on the bottom

Starting sides
Within 4 feet on the bottom and just getting started on the sides. It's getting curvy at the bow.

Slow work at the front
Here I'm getting to the more concave portions. The planks require more fitting and staples to hold the planks.

Finally closing it up
It's been a long time coming.

Layer one complete
Planking the first layer took me ~80 construction hours. Each plank is hand fit. I could glue up about 4 at a time.

Fairing paid off.
Each plank lays flat on all the surfaces (yay!). The second layer will go faster.

Vacuum pump
This pump arraignment (from joewoodworker.com) has a pump, vacuum reservoir, vacuum switch, gauge and power switch.

Total of four bottom baggings
I'm doing larger and lager areas as I get the feel of how much the pump can keep up with.

Here is yet another section.
My largest yet at ~18 square feet. I'll try for more area when I get to the sides.

First attempt at vacuum bagging.
My first attempt at vacuum bagging went very well.

First Section of bottom bagged
Getting better at the operation.

Second layer completed
There is a third bottom layer. The finish layer, mahogany, will then go over the these.

Mahogany bow planks
I have a total of 4 bottom layers here, and 2 on the sides. The sides will get Mahogany next.

Here are the first 4 planks
You can see the yellow rope to help *spread* the vacuum around.

Here are the 4 planks in place.
Three more on this side and then I'll turn the boat around to do the other side.

Here is the unfinished side
I did a lot of extra reinforcing to make sure the casters held the boat up.

Do a 180
Here you can see us putting the boat back in the shop the other way so I can finish the final layer.

First side complete
I did the initial long boarding here so the coloring of the *planks* looks a little off..

Installing the strut and rudder
Preparing for shaft drilling. I've spent a lot of time checking and drawing to get it right.

Completed Alignment
Strut, rudder and shaft hole. After lots of double checking - the hole came out in the correct spot! Yay!

All Planking Complete!
Here is the first pass at Finish sanding the transom. I'm guessing I have 40-50 hours more before the flip.

Here are the two parts of the new cradle. I will put stretchers inbetween the front and back so they don't move ar
Here are the two parts of the new cradle. I will put stretchers inbetween the front and back so they don't move ar

A shot of the side going back. I have a couple more coats to go before flipping the hull
A shot of the side going back. I have a couple more coats to go before flipping the hull 2004-10-24

My first coat of varnish on the transom. I finally figured out the proper way to spray using HVLP. This is so much bet
My first coat of varnish on the transom. I finally figured out the proper way to spray using HVLP. This is so much bet

Varnishing completed for now - Next turning the hull
Varnishing completed for now - Next turning the hull 2004-10-26

My boat is finally right side up - it seems to take up more space this way!
My boat is finally right side up - it seems to take up more space this way! 2004-10-31

View of the left side on the cradle.
View of the left side on the cradle. 2004-10-31

Right side of boat after flipping the hull
Right side of boat after flipping the hull 2004-10-31

Inside the bow view after flipping the hull
Inside the bow view after flipping the hull 2004-10-31

View of the inside toward the transom
View of the inside toward the transom 2004-10-31

Here are the first two laminations of the deck clamp fit and glued into place. There is a bit of effort involved with f
Here are the first two laminations of the deck clamp fit and glued into place. There is a bit of effort involved with f

Here are the beds being measured and tested in place
Here are the beds being measured and tested in place 2005-02-12

I started by making a rolling cart to work on the motor beds
I started by making a rolling cart to work on the motor beds 2005-02-12

Motor is hanging from chain hoist through bolted to the cross member above my garage door. I put the jib sheet from my
Motor is hanging from chain hoist through bolted to the cross member above my garage door. I put the jib sheet from my

Finally the motor is in place. Now to fit everything around it..
Finally the motor is in place. Now to fit everything around it.. 2005-02-13

Here is the hatch framing near completion
Here is the hatch framing near completion 2005-03-06

Here is the hole in the transom. I used a Jasper router hole cutting jig and made precut the hole leaving two small tab
Here is the hole in the transom. I used a Jasper router hole cutting jig and made precut the hole leaving two small tab

The exhaust trumpets in place.. Just how I wanted them to look.
The exhaust trumpets in place.. Just how I wanted them to look. 2005-03-27

Here is the exhaust pipe beside the fuel tank - even without the tank - the bend would have been tough. I will most lik
Here is the exhaust pipe beside the fuel tank - even without the tank - the bend would have been tough. I will most lik

Here is my exhaust pipe layout - I'm not sure if I like it at this point... I need to do a bit of research and see
Here is my exhaust pipe layout - I'm not sure if I like it at this point... I need to do a bit of research and see

There were no off the shelf elbows to get around the corner that I needed. I found out I could make them myself. Here
There were no off the shelf elbows to get around the corner that I needed. I found out I could make them myself. Here

Here is my temporary instrument cluster to keep an eye on the engine.
Here is my temporary instrument cluster to keep an eye on the engine. 2005-05-30

I didn't like the previous exhaust hose layout - It took a lot of checking to come up with this simple layout. I d
I didn't like the previous exhaust hose layout - It took a lot of checking to come up with this simple layout. I d

Finally - the first test run. Engine and exhaust sound great. They ran perfectly.
Finally - the first test run. Engine and exhaust sound great. They ran perfectly. 2005-05-30

Here is the initial setup of the rear seating area with ceilings and mufflers still exposed.
Here is the initial setup of the rear seating area with ceilings and mufflers still exposed. 2005-07-06

2nd row seating in front of engine compartment going into place.
2nd row seating in front of engine compartment going into place. 2005-08-21

The Deck battens have just went in and are being faired now.
The Deck battens have just went in and are being faired now. 2005-10-15

Here are the bow deck battens
Here are the bow deck battens 2005-10-15

Fairing the deck was infinetely easier than the hull. The concave hull was tough to work with. The convex deck is simp
Fairing the deck was infinetely easier than the hull. The concave hull was tough to work with. The convex deck is simp

I get lots of questions about vacuum bagging. Here you can see the top layer of stained mahogany with 4oz glass and MAS
I get lots of questions about vacuum bagging. Here you can see the top layer of stained mahogany with 4oz glass and MAS

The front seats will be bucket style so people can easily take turns driving. It's been a bit of mental gymnastics
The front seats will be bucket style so people can easily take turns driving. It's been a bit of mental gymnastics

Here is the completed rear seating with the deck battens in place.
Here is the completed rear seating with the deck battens in place. 2005-12-27

I wanted toskip and do something different, here is the sub deck temporarily installed. This portion of the boat is don
I wanted toskip and do something different, here is the sub deck temporarily installed. This portion of the boat is don

There are the beginings of the ceilings. When done, I will round over the planks so thel look a little more like beadbo
There are the beginings of the ceilings. When done, I will round over the planks so thel look a little more like beadbo

The front seats are bucket style, but build into the hull. My intention is for them to be removeable (w/effort). These
effort). These 2006-01-03

Here are the completed front seats. These will be the permanent backs and bottoms. The idea is they will help make the
Here are the completed front seats. These will be the permanent backs and bottoms. The idea is they will help make the

The frames I mounted the ceilings to are two laminated 1/4" plywood straps that hold a fair curve for the ceilings
4" plywood straps that hold a fair curve for the ceilings 2006-01-16

Here is the front subdeck temporarily installed. Final installation included gluing the subdeck to the deckbeams and ba
Here is the front subdeck temporarily installed. Final installation included gluing the subdeck to the deckbeams and ba

I made a 6" radius template that I screwed into place and copied with a pattern copy router bit.
I made a 6" radius template that I screwed into place and copied with a pattern copy router bit. 2006-03-08

Here ar the cornerblocks being installed at all of the cockpit corners
Here ar the cornerblocks being installed at all of the cockpit corners 2006-03-10

The finish covering board is only 1/4" thick. Here is outer blocking as per the plans to make it look like there i
4" thick. Here is outer blocking as per the plans to make it look like there i 2006-03-12

For the Covering boards, I layed a batten the full lenght of the hull just touching the cockpit openings and made sure i
For the Covering boards, I layed a batten the full lenght of the hull just touching the cockpit openings and made sure i

Once I got the inside profile of the covering board fair, I resaw so that they are perfectly matched left to right. For
Once I got the inside profile of the covering board fair, I resaw so that they are perfectly matched left to right. For

Here are the bow covering boards pinned in place after final fitting.
Here are the bow covering boards pinned in place after final fitting. 2006-03-25

Because the covering boards have a lot of surface area and they would be very difficult to repair if they did not bond w
Because the covering boards have a lot of surface area and they would be very difficult to repair if they did not bond w

Here - the king plank is in place and the first of the deck planks have been glued on. I kept it simple and went with 1
Here - the king plank is in place and the first of the deck planks have been glued on. I kept it simple and went with 1

Here are the next sections of deck planks being installed. It takes a while to get all of these in and out. I spend 1
Here are the next sections of deck planks being installed. It takes a while to get all of these in and out. I spend 1

Each of the deck planks that meet the coving boards needs to be custom fit. Here are the first 3 that meet the bow. S
Each of the deck planks that meet the coving boards needs to be custom fit. Here are the first 3 that meet the bow. S

Here is the completed Decking. Next is a bit of fairing and sanding. Once the deck is fair, I will install the rubrails
Here is the completed Decking. Next is a bit of fairing and sanding. Once the deck is fair, I will install the rubrails

In addition to the hand plane, I uses a pneumatic longboard for sanding and a 5"x10" piece of 1/2" plywoo
2" plywoo 2006-06-16

April and May are Slow boat building months around here because I'm getting my sailboat ready for the season and th
April and May are Slow boat building months around here because I'm getting my sailboat ready for the season and th

More Planking detail
More Planking detail 2006-07-09

I hope the color comes out ok..
I hope the color comes out ok.. 2006-07-09

A closeup of the 1/8" Gap in the deck planks
8" Gap in the deck planks 2006-07-09

Here are the covering boards stained with a combo of Solarlux Brown Walnut, Transtint dark walnut and a little black. I
Here are the covering boards stained with a combo of Solarlux Brown Walnut, Transtint dark walnut and a little black. I

I Need to do a better job of getting the Sikkaflex into the 1/8" false seams that I made. I managed to get it all
8" false seams that I made. I managed to get it all 2006-10-02

Completed the backof the boat. All of the wet sanding done. This section used almost an entire tube (caulking gun tube
Completed the backof the boat. All of the wet sanding done. This section used almost an entire tube (caulking gun tube

Now to start putting the interior in for the last time.
Now to start putting the interior in for the last time. 2006-12-17

Deck Varnished after completing stain and caulking. Needs 4-5 more coats ov varnish, wet sanding and polishing
Deck Varnished after completing stain and caulking. Needs 4-5 more coats ov varnish, wet sanding and polishing 2006-12-

I used a drill with a sharpened coathanger as a bit to pop holes through the deck from the hatch framing underneath. Th
I used a drill with a sharpened coathanger as a bit to pop holes through the deck from the hatch framing underneath. Th

Here the trim has been cut and fit. Now I can complete the deck cutting out the hatches and do the finish work on them
Here the trim has been cut and fit. Now I can complete the deck cutting out the hatches and do the finish work on them

Here I have all of the deck fittings in place, holes cut (without incident, whew)
Here I have all of the deck fittings in place, holes cut (without incident, whew) 2007-01-05

First Mockup of the dashboard..in MDF. I need to adjust a few positions of the items. But not a bad first try.
First Mockup of the dashboard..in MDF. I need to adjust a few positions of the items. But not a bad first try. 2007-01

This one shows that the interior is completely removable. I'm guessing that someday I'm going to need to get b
This one shows that the interior is completely removable. I'm guessing that someday I'm going to need to get b

Dash Detail
I'm also adding a bead detail to the bottom edge of the dash board.

Since the boat is all buttoned up in shrinkwrap, I started the dull task of staining and sealing the ceiling boards. Th
Since the boat is all buttoned up in shrinkwrap, I started the dull task of staining and sealing the ceiling boards. Th

The finish work is not complete, but it is time to get a trailer made. Since it is a custom hull - the best way to get
The finish work is not complete, but it is time to get a trailer made. Since it is a custom hull - the best way to get

Ready for a trailer
Finally - The project is at a point where I need to get a trailer made. I've chosen to go custom from a manufacturer.

Movement on cradle
Somewhere during the last half mile to the trailer shop (which is on a mountain!) - the boat worked itself forward

Trailer Shop
We made it to the trailer shop. Boat suspended from their gantry system. It has a strap at the rudder and bow

Varnishing is hard.
Varnishing has turned out to be a time consuming, painful process. Here are some varnish zits on my last coat.

Polished Deck
After all that sanding and compounding.. I finally got a good finish. I salute anyone who can varnish right the first

Wet Sanding Deck
The solution is to wet sand. I hand sanded with 400, 600, 800, 1000, 1200 and 1500 grit papers. Then used 3M Finessit

Painting Stripes
Since all of the Sikkaflex is yellow from varnish - I'm now painting them white. Turns out this is common practice..

Front Deck
White and Yellow lines... White is much better..

Cutwater Template
My first attempt - We'll see if I stick with this design or change it up..

Dash wiring nearly complete
Steering hole will be cut once seats are completed. I want to make sure it gets centered properly!

Connectors
Discovered they come apart..

Much easier to crimp
W/o the plastic on - they are easier to work with..

Shrink Wrapped
They require smaller - less expensive shrink wrap and make a neater connection. I wish I did this a long time ago..

Behind the Dash
I've spent a few hours curled up in a ball to get the final connections completed. There are many more all over the boat

Raw Ceilings
Here are the pre-fit mahogany ceilings

Stained
The Stain is Interlux. It goes on thick and takes quite a while to apply and wipe.

Rear seating
Some completed ceilings in the rear. I plan on making a custom cover for the exposed areas.

Middle Seat
Ceilings in place. Plenty of details left to work on..

Glove Box Cover
Small dash items being varnished

Hatch
Here is the inside of the hatch, stained with 3 coats of varnish

Cutwater
The finished cutwater in place. They are pretty tricky to get installed properly.

Setting Sling for front of boat
We are using eye bolts through the header and a 10,000lb tie down strap to hold the front

Portable Fork Lift
The hand crank lift will get the rear off the cradle

Boat suspended in shop
Happy to get it on its trailer for the last time

Hanging on
Its creepy having all your work hanging like this. But all was safe - No creaks of groans (from the boat)

First Daylight pic
Taken from the shop roof. Getting close to upholstery

Another roof shot
Direct sunlight reveals many blemishes hidden in the florescent light of the shop. Need to touch up some areas

Trailering to the Upholster
Ok. The boat is huge! it doesn't weigh much - but it's big. Got lots of thumbs up on the ride.

Sea trails Launch
First time down the boat ramp

Floating at the Ramp
No Problems here

Tow to Dock for Prop Calibration
The first time out - need to get shaft alignment perfect - no motor yet.

Pulling up to dock for first time
Preparing for a landing

First cruise
It went forward when I put it in forward!

Couple's Cruise
Wife and I out testing the boat

Running Pics
We were lucky to have a chase boat

Gets on plane quickly
We had a good photographer

Motoring back to the house
Nice flat water from under

Cruising
.

Approaching Dock
.

More Willing Passengers
The back is the best seat - very comfortable.

We get a ride too
.

Sits perfect on waterline
Boat sits on the designed waterline both fore

And aft
I'm very happy with the trim

Sitting on Dock
.

Dock
.

Doug and Jackie
.

Bow Shot
P5264329.JPG 2008-05-26

Gauges
.

23K Gold leaf
Got a stencil made for the transom. Started gold leaf work.

Gold work continues
Adding the gold is tedious. It is lighter than air it seems. You need to hold your breath while placing gold onto transom.

Lettering ready for a coat of varnish
Lettering came out nice. I will coat with varnish and get professional painter to paint the outline.

polishing glass
The glass company did a horrible job and I could not get the edges cleaned up professionally. So I finished the edges myself with a diamond stone.