Project 3 -Aft stem bar, gusssets ect

We hadn't previously realized that putting in the transom will be no easy job! We found that after measuring, checking, cutting, rechecking, remeasuring, welding, cursing, and finally throwing away the mock transom frame , it would have to be done once the rest of the plate is on!
May the force be with us for that day.... Sometimes new and radical methods work, but mostly they don't. We did learn a few things though: 1) You can't mimic a piece of plate having multiple curves with a frame.
2) The transom isn't flat!!( See pic to right) 3) If things aren't going your way, just stop and come back to it another day, if possible. ( Presuming you don't throw it away first! ) 4) It might be a good idea to try to find a photo of the boat you plan to build, already built by someone else so little things like the transom being curved become obvious!

At last some real construction on the boat!
Today we bent the aft stembar, a 3/8" by 2 1/2" flatbar slightly curved to accommodate the aft upward curve to the transom. Things went smoothly and we had it in place in no time at all. We then snaped off the two closest stringers and pulled them into it, only to avoid possible later clutter by having them all join at the transom.
Next we aligned and leveled all of the webs at the foot of the keel, cutting slots into each ones center and putting a long piece of 1 1/4" flatbar on edge into the slots. After we were sure they were all exactly vertical, we tacked it on. Suprisingly none of the frames moved at all over winter so no adjusting was necessary.

Welding in support to keep keel frames aligned

We were thinking about putting in the heel bar ( aft of the keel ) but the angle would have to be determined by the type of motor we will be putting in. The optimum angle is 90 degrees to the prop shaft, and all engines sit at a slightly different angle. We're not sure how much of a difference this will make performance-wise, but it sure would look nicer!

This week we will have to decide on which engine to go with. We are leaning towards Yanmar. ( Excuse the pun! )
The radius plate, pre-formed has been ordered, but won't arrive for 2 weeks so we haven't much to do for a while except the dreaded grinding and priming of the frames and stringers. It's amazing how long it takes to do what seems like such a small area! We found that all means of cutting off mill scale are tedious next to using a grinder. ( Or sandblasting of course!) Unfortunately we found the grinder became too heavy after a while, especially when grinding under the stringers, so we went and bought a smaller light duty one for that and it is great for getting into tight spots without making too much of a mess.
Slowly the framework is becoming red with primer. For us priming the frame first has many advantages even though some of it will have to be removed before welding on the plate...

The boat is being built outside, in a more wet-than-dry climate, and rust happens quickly
I feel the neighbors are likely sensitive enough to our " skeleton of steel " let alone it being rusty. ( People, including myself, tend to have thoughts of junkyards at the sight of rusting steel! )
Red primer disguises it as a big red bike!
Once the boat is plated, those hard tho prime areas won't have to be.

I don' recommend this method to anyone because we have no idea how it will turn out, but we do know the fumes given off by welding on primer can be harmful.

Although it is generally recommended that the gussets were to be tacked in only, we decided to weld them in solid anyway. The way I figure it is if that area of the boat isn't right, then what is?!
The stem bar must stand proud a little to accept the hull plate, and we tested it with some scrap.

Gussets cut and ground

Once again grinding them off before putting them in was a good idea. I know it sounds silly but sometimes we forget! (Like with the web floor for frame three!) Weather was co-operative, at least for the first half of the day, when rain cut it short.
Earlier on, while I went and had my morning sail in our little 21 footer, loosing my wind, getting stranded in the

weeds on the other side of lake, and burning out the water pump in our Mercury outboard, Gena took it upon herself to build the car for our hoist. She used 4 boat rollers bolted between two plates and a 1 1/2" bolt at the bottom. It seems awfully stiff though so we may have to rethink that, all depending on what Princess Auto Parts has in their bargain bin next time we're there! It's looks nice though doesn't it?

View from high up - Gena testing her "car"

Even though we have a tent to work under, a lot of the cutting of larger plate will have to be done outside. As we will be on the ocean, we are completely at the mercy of mother nature.

Once again the weather has been rather uncooperative, rain on and off all day. The tarp was dragged on and off many times today. Nothing like instant rain cover! Today, besides finishing off the gussets, we put on the aft keel bar and rounded in it's subtle curve towards where the rudder will be. Scary!! Our first piece that will be exposed to the elements and won't be changed!
The curved part aft is actually another small piece of 3/8" added on. No job to big or small for the plasma cutter. The frame sure looks nice all primed up, too bad we have to mess it all up again with the nasty plating. All of the neighbors are coming by to have a look. Guess we'll have to start selling tickets ha ha!