The First Step

We are putting another 17 into production because Santa cannot do boats like we here at Sage do.  In the many steps it takes to get from beginning to end, the first one is to make the bulkheads and stringers so that they can be put into the boat layup in Lamar, CO.  Each boat uses one full sheet of 3/8″ marine plywood which I keep on a rack here in the shop.  I have it set up so that I can pull a sheet, take 10 steps, put it on the slider for the table saw, and cut it up in less than 2 minutes.

plywood ready to be cut up for bulkheads

plywood ready to be cut up for bulkheads

Once it is in four workable pieces, I use the patterns that Jerry made and simply trace each pattern onto the plywood and then cut it out using a jig saw with an aggressive blade.

pattern for bulkhead on plywood ready to be penciled and then cut

pattern for bulkhead on plywood ready to be penciled and then cut

The stringers and under cockpit bulkheads have access ports that are marked from the pattern and drilled out with a 5″ hole saw.  A nice touch is to then do a 1/8″ roundover on these access ports so when you stick your hand in there it feels soft and not sharp.  Wrap these up in plastic like a Christmas present and we have the birth of a new 17.

cutting out access ports with a hole saw

cutting out access ports with a hole saw

Matt

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