Cedar-Strip Canoe
The final cedar strips are fit into place along the strong back.
We divided into two groups, each of which would build a complete cedar-strip canoe. Eagerly, the groups launched directly into the boatbuilding process. The first step involved setting up forms on strong backs-wooden beams on which each canoe would be built. The forms, or stations, define the boat's shape and are set up at intervals along the strong back. We learned that it is essential to properly align the forms because once you begin applying the strips, you can't go back to make adjustments. Misaligned forms will produce a crooked boat. Believe it or not, another critical step is applying masking tape to all the edges of the forms to prevent the hull from being permanently glued to the forms. When Gustaveson was asked what would happen if this step were omitted, he smiled and said, "There isn't much you can do except strike a match, make a nice bonfire, get out the marshmallows, and cry by the firelight." It seemed to me that he was speaking from experience.
Once the forms have been secured to the strong back and properly aligned, the stripping process begins. Starting at the sheer line and working upward (toward the keel), each strip is bent around the forms and secured with staples and glue. As we continued the stripping process, the boat slowly began to take shape. Gustaveson patiently demonstrated techniques, answered questions, and helped us stay on track. Once, when I was having trouble getting a strip to fit just right, he came by and took out his pocket knife. With just a stroke or two, he shaped the end of that strip to a perfect fit. One of my group members, Rick, leaned over and whispered, "I bet he could build a boat in the Boundary Waters with nothing but that knife if he had to." It is obvious that Gustaveson enjoys building boats and teaching students how. Even when we made mistakes, he would tell us, "Don't worry, you can't make a mistake that I haven't already made. This isn't rocket science. Just take your time and be neat."
When the stripping was completed, the class removed the staples and smoothed, or faired, the outside of the hull, first with a block plane and then with a random-orbit sander. The hull was sealed and strengthened by applying a layer of fiberglass cloth and several coats of epoxy resin. The stem and stern received several extra layers of cloth for added strength. The hull was then lifted off the forms and turned over so that the process could be repeated on the inside of the hull.
In my opinion, fiberglassing is the technique that would have been the hardest to self-teach and achieve satisfactory results. Once the hardener is mixed and the epoxy begins to cure, there is a limited amount of time with which to work. I wouldn't want to have to phone and ask for instructions in the middle of glassing. Again, there's a big difference between reading how to do it and having someone show you how.
Al Gustaveson shares tips for applying the first coat of epoxy resin.
After a final sanding of the epoxy, we entered into the last stages of construction. By that time, we had spent nine evenings working together toward the finished product. Little remained to be done after fitting the gunwales, thwarts, and yokes. Small decks were installed in the bow and stern, and seats were hung from the gunwales. The final step was to apply two coats of varnish to the hull to protect the epoxy from ultraviolet rays.
Right before our eyes stood the finished product. The transformation from a pile of wood to a beautiful, functional cedar-strip canoe was complete. We all admired it for a few minutes, and ran our hands appreciatively along the hull.
I asked Gustaveson if people ever decide not to put their boat in the water. "Actually," he said, "that does happen sometimes. For some guys, it's all about the process. They build a boat because they are looking for a project. For me, the fun starts when you take that boat out those doors and put it in the water."
On the last night of our class, there was still one task to be completed. We all wrote our names on slips of paper and put them into a coffee can. Two names were drawn to determine who would take the two boats home with them. Rick's name was drawn from my group. As we left, he was already planning his next trip to the Boundary Waters. I'm sure that someone will stop to admire his canoe and ask, "Where did you get it?" I hope that Rick replies, "I built it myself, with a little help from my friends!"
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