Home Built Paddle Wheel Boat Build

[AyatollahGondola]

Hey all!
I am always building things around here, Sheds, garden planters, sheds with garden planters on top, treehouses, etc.
I've been planning a boat building project for a few years, and it's finally getting the bones ready for assembly. I am building this from plans that were in an ancient Popular Mechanics magazine from the early 1960's. It's a small craft for two adults, or possibly 2 adults and two kids.
I will be deviating from the plans a bit, but for good reason. The original plans called for the paddlewheels to be hand cranked. I'm going to make it into pedals so you can lean back, kinda recumbent style. Also deviations in wood thickness, coatings, and screws because a lot has changed since the early 1960's.
Progress will be posted here

[AyatollahGondola]

Finally time to start assembling the boat. Everything must be lined up and trued before drilling pilot holes. I use wood shims underneath, and furniture clamps to hold it. After it's set. then pilot holes are drilled for the screws. Then the clamps come off, waterproof glue applied to the joints, and then re-clamp it, but this time screws put in the pilot holes.
After the glue cures, the clamps come off, and we're ready for plywood to be put on for the bottom of the boat. This is why it's important for it to be trued before drilling, screwing, and glueing. The plywood must fit properly, and it won't if your frame is askew

[AyatollahGondola]

I drilled the holes for screws using a countersink bit, and then drove marine grade screws in. I had to hunt around town for some good waterproof epoxy for the joints. I settled on one that needs mixing, but it was an easy mix. I then unscrewed one corner of the boat at a time, and applied the epoxy to the joints. Next, re-set the wood into the rabbeted ends, line up the screws a bit and clamp both joints on one side of the boat, tightening the clamps and screws a little each time until both are snug, and the screws slightly recessed. Let set for 24 hours, and then repeat on the other side. It's important to buy an epoxy that is waterproof rated for below the waterline, and....get one that isn't fast drying. Especially stay clear of the ones that say "contact glue or cement or what have you. Once those touch, they stick for good. You want one that's forgiving while you align and tighten.

[AyatollahGondola]

I spent a few days clamping the hull ply to the frames to kind "train" the wood to its' form before actually attaching it

[AyatollahGondola]

Next up came actually attaching the hull plywood. It has to be done with both screws and epoxy, so you're racing the clock a bit. Apply epoxy to the frames and then start drilling and screwing from the center out

[AyatollahGondola]

Next up was coating the hull outside for a water tight bond

[AyatollahGondola]

After the hull was finished, I moved on to constructing the paddle wheels. Here I stumbled because the more the half century old plans were not complete, and what was there proved inaccurate in places. I had re-calculate angles and actually make guesses from pictures

[AyatollahGondola]

With the paddle wheels constructed, I then set out to make the cranks. The original plans called for it to be hand-cranked, but I wanted foot pedals. This proved a lot harder to do than it sounded. I tried to have a local machine shop just bend 5/8 steel rod into shape, but they tried and couldn't. Too many bends in a short distance. So I used 1/2" black pipe with a lot of elbows, tightened them up in alignment, then welded them at the threads. To make the actual pedals I used some old poly top cutting boards cut into shape, screwed them together, and then drilled out the center so they can be screwed back on to the pipe. I drilled small holes on the ends of the pedals to inject grease for lubrication

[AyatollahGondola]

Finally, some good paint, and then attaching the cranks. For seats, I temporarily mounted some stadium chairs we got at costco for cheap. Later I'll have some wooden ones that will tilt and adjust to fit leg length. I did end up building a rudder out of excess frame wood and a bunch of hardware laying around the place I fashioned together using the welder.

[AyatollahGondola]

The maiden voyage came in Late june. The boat performed magnificently in general, although I do need some short fenders over the paddlewheels to keep water from splashing in. My steerage work perfectly really, but because the cranks can be pedaled separately from each side, you can steer that way when two people are pedaling.. Sooo Many people came over and commented on the boat. Lots of smiles, thumbs up, and questions. A short video is attached of the paddlewheels in action. I was able to load and unload from the truck without help, and I added some removeable launch wheels which are available on the cheap. Also you can see an umbrella which proved to be quite valuable for the summer sun, and I used a flag pole bracket to mount it