A POND BOAT PHOTO ESSAY

Dave Thorne (Herb's Dave) Built a Pond Boat
It took him about a Week to Build (Hobby Hours)
(Materials (Without FiberGlass) Cost roughly $300.)
A www.cruisemyroute.info Administrator was there
(most of the Time) and captured the Endeavor
via Photos and Observation.
Now you, too, can see a Pond Boat being made.

BoatFinished8 PL Cement BoatFinished10
PL Premium Seals/WaterProofs the Pond Boat
Apply a Bead of PL Premium to Every Join on the Boat

BASIC MATERIALS
(unFinished Dimensions)
Cavendish Castle, 588-7800
Call Cavandish Castle to get Prices on Materials
2 Sheets of 3/8" PlyWood:
(DECK, STERN, KNEES, OARS)
1 Sheet of 1/4" PlyWood:
(PLANK)
1 - 10' Length of 2 x 4 (6.7 BF):
20' x 7/8" x 2" (3 BF) (BACKBOARDS)
20' x 5/8" x 2" (2 BF) (GUNWALES)
Total Needed = 5 BF
2 - 8' Lengths of 2 x 4 (10.6 BF):
2' x 2 x 4 (1.3 BF) (STEM)
24' x 7/8" x 2" (3.5 BF) (FRAME STRIPS)
16' x 1/2" x 2" (1.3 BF) (RAILS)
20' x 5/8" x 2" (2 BF) (KEEL STRIPS)
Total Needed = 8 BF
3 - 8' Lengths of 1 x 6 Board (12 BF):
2 - 6' x 1 x 6 Board (8 BF) (OARS)
3' x 1" x 2" (0.5 BF) (STERN TRIM)
3' x 1 x 6 Board (1.5 BF) (STERN STRIP)
Total Needed = 10 BF
10' of 12" Board (10 BF):
(TAUTS, BOW SHELF)
2 Tubes of PL Premium
1-1/4" & 1-1/2" Screws
1" Nails
About 6' of Nylon Rope :
(STEM & STERN ROPES, OARLOCK TIES)


Marchs Enterprises, BlakeTown, 759-2570
Call Marchs to get the Prices of Paint etc
2 OarLocks
Marine Paints

Note:
Saunders SawMill
Greens Harbour
(709) 683-1213

Stocks unFinished/Finished Lumber
Call Saunders SawMill to get Prices on Lumber

Basic Tools:
Hammer, ScrewDrivers, Level, Plane,
Tape Measure, Pencil, StraightEdge
HandSaw, BandSaw, JigSaw, SkillSaw, TableSaw,
Caulking Gun, Angle Measure, Putty Knife,
Drill, Knife, PaintBrushes, ChalkLine
Bar Clamp, C-Clamps, Flexible Strip

The Pond Boat Described here is FiberGlassed on the OutSide.
(Dave Planked it with 3/16" Merante)
As FiberGlassing isn't included here,
she maybe should be Planked using 1/4" PlyWood
(Maybe use Kerfs to Bend toward the Bow)

Note: This Coverage of the Building of a Pond Boat is Compiled by People who are NOT Pond Boat Builders.
The following OverView/Description is NOT to be Considered as, in any way, being an Authority on Building a Pond Boat.
Neither Dave Thorne, nor the Compilers, hold any Responsibility for anything that occurs during the Building of a Pond Boat.
cruisemyroute.info Administration

SITE CONTENTS
Horses > Stem > Stem > Knee
Stern > Frame > Bend > Planking
Gunwale > Strips > Bow Shelf > Taut/Tail
Keel Strip > Paints > Oars


1: Deck
Mark Draw Shape
Cut a 10" Strip off of a Sheet of 3/8" PlyWood
This is the 38" Wide (at midShips) Deck

Use a Flexible Strip to Mark Deck Curves
Bend the Strip (use Nails as Posts to Hold it)
Mark the Curve
Do the same with the midShips/STERN Curve
The STERN is 34" Wide

Use Cut Pieces to Trace Curves on other side

Horses
Plane the Edges
Put the Deck onto SawHorses
CONTENTS

CAUTION
When Using Power Tools,
wear Safety Gear and
ALWAYS follow Safe Practices.
This Cutting Technique
is NOT a Safe Practice.
CONTENTS

2: Stem

20Degrees Stem Top
Use a 2' piece of 2 x 4 for the Stem
Cut the Stem from an 8' Piece
(Trim it to Length after Planking is done)
Rip the Stem to Match the Shape of the Deck
(This will Allow for Secure Attachments to the Stem)
Seal the Join with PL Premium
Use 2 Screws to Attach the Stem
(through the Bottom)
to the Deck.
Stem Trim Stem BackBoard
BoatFinished4 PL Cement BoatFinished6
PL Premium Seals/WaterProofs the Pond Boat
Apply a Bead of PL Premium to Every Join on the Boat
CONTENTS

3: BackBoard

BackBoard Kerfs
The BackBoard follows the
Shape of the Deck
It serves as a Deck Thickener,
(to which the Lower Planking is Attached)
Rip 2-10' Lengths of 7/8" Strip from
a Piece of 10' 2 x 4
(Bottom of BackBoard is 7/8" Wide)
Rip the Bottom of each BackBoard at
15 Degrees,
to Match the Outward Slant of the Planking
Cut the Kerfs where the BackBoard
Bends the Most
Front Cut Cement
Bend Repair
Use a Bar Clamp to hold the BackBoard in
place while attaching with Screws up
through the Deck
Build and Install a BackBoard for each Side
To Repair Cracks, apply PL Premium
to the insides of the Cracks
Clamp Cracks and
leave in place OverNight
CONTENTS

4: Knee
Template
The Knees are Corner Joins that Secure the
Frame upRights to the Frame Bottoms
(Frame Boards are 7/8" Strips cut from 2" x 4")
The Legs of the Knees are:
about 8" Long and 2" Wide
The Knees are Nailed to Frame Corners
The Pond Boat has 14 Knees.
(4 per Frame + 2 for Stern Frame)
On a Piece of 3/8" PlyWood,
Trace the Legs of the Knee using a Strip of Frame Board
Use a Can to Form the Curves.
(The First Knee is a Template)
Make Knee
Knees used from midShips to STERN are
Slanted 15 Degrees Outward.
The Same Knee Shape can be used for
Knees from the Stem to midShips
(with Minor Adjustments to the Slope)
Adjust Knee Angle as Needed
Use a BandSaw to Cut the Knees

Build Frame Frame-Knee PL Premium
The Knee CutOuts allow the Frame to Sit
on the BackBoard and to be Flush with the
OutSide of the BackBoard.
(for an Even Surface to Attach the Planking)
Put a Bead of PL Premium between Frame
and the Knees
Install Knee
FinishedCornerKnees
Nail Knees to the Frame Boards
Use Several Nails per Knee.
CONTENTS

5: STERN
STERN Frame Fit 26STERNbuilt
Build a Frame to fit the STERN End
(Stern Frame has Knees on the
InSide Only)
The Stern Frame sits on top of the
End of the Deck and Straddles the
BackBoards.
(Secure with a Coat of PL Premium)
Use a Piece of Flexible Strip to Mark
a Curve on the STERN PlyWood.
Cut the Curve
(Coat Frame with PL Premium)
Screw PlyWood to Stern Frame
Make sure that the PlyWood will
Extend to Beyond Bottom of Deck.
Trim later
Stern PL Premium Install STERN
Put a Bead of PL Premium across the Stern Deck
and onto BackBoard Ends
Install the STERN using Screws
through the BackBoards
and up through the Deck


STERN OverLay Detail
This CutAway shows that the STERN PlyWood
covers the Ends of the BackBoards and the
End of the Deck PlyWood
(Coat Deck/Backboard Ends with PL Premium)
Planking Covers the Sides of the STERN
This is a Frame Corner Detail
showing the PlyWood Covering
the End of the Backboard

BoatBow PL Cement BoatStern
PL Premium Seals/WaterProofs the Pond Boat
Apply a Bead of PL Premium to Every Join on the Boat
CONTENTS

6: Frames

Frame Length Frame Base
For each Frame Base,
Rip a 7/8" x 2" Strip (from 2 x 4) to Extend
to beyond the BackBoards
Cut the Ends of the Frame Base to Match
the Slants of the BackBoards
Frame Cross Section Mark Frame Cut
CutAngle Cut Drainage Holes
Cut out Notches at the Ends of the Frame Bases
such that the Frame upRights will be Flush
with the Outer Edge of the BackBoard
FrameDetail Frame Corner
Build Frame Bottom Screw Frame
Frames Braces
Brace the Top of each Frame
Back to Knees
CONTENTS

7: Bend Deck
Bend After 3 Frames Installed Bend From Ceiling
After the Frames are Installed,
it's time to Bend the Bow up
(to Ride the Waves)
The SawHorse will Hold the Bow up
Put a Piece of Board onto the Deck,
to Protect the Deck Wood
Force the Deck to Bend about 3"
BendRodLevel
As the Next Step is Planking,
it is Critical that the Boat be
Level from Side to Side
CONTENTS

8: Planking
Hull Sheet Fit PlyWood on Side
Cut a Sheet of 1/4" PlyWood LengthWays
in the Center
Fit the PlyWood such that it extends
Above the Gunwale and Below the Deck
As the Sheet is being Attached,
ENSURE that the Boat remains LEVEL
You will Trim the PlyWood later
Put a Bead of PL Premium onto the
Stem, Frames, STERN and BackBoard
Side One Screw OneSideUp
Cover the InSet Screws with PL Premium
Use a Putty Knife (for example)
to Scrape Excess PL Premium
from the InSet Screw holes
You'll Need 2 Pieces of 1/4" PlyWood
to Cover the Gaps at the STERN.
Put a Bead of PL Premium
EveryWhere that the PlyWood
Joins Wood.
Trim Stem PlyWood Two Sides Planked
The Sides are:
18" High at the Stem and
14" High at the STERN
Use a Flexible Strip
to Mark a Smooth Line
Saw off the Excess PlyWood
Planking is Finished
CONTENTS

9: Gunwales
Gunwale
Rip Enough 5/8" x 2" Strip from 2 x 4
to screw Gunwale Strips
to the inside and the outside
of the Top of the Plank (40')
Plane the Edges that will be on
the Tops of the Gunwale

Cut to Fit Gunwale Strips
between the Tops of the Frames
CONTENTS

10: Strips
Grey Paint Deck Strip
Rip a 2" Strip (from 1" x 6" Board)
to Attach to the Top of the STERN
Rip a Strip to Attach under the
Top Strip of the STERN
Plane the Top Corners

Drill Two 5/8" Holes into the STERN,
to Attach a Piece of Rope
(for Lifting the Boat at the STERN)
Drill a 5/8" Hole into the Stem,
to Attach a Piece of Rope
(for Lifting the Boat at the Stem)
Rip Enough 5/8" x 2" Strip from 2 x 4
to run the Length of the Boat
This will provide a BackBoard
for Attaching the Keel Strip
Plane the Top Corners of the Strips
Apply a Bead of PL Premium
Screw the Strips onto the Deck
CONTENTS

11: BowShelf
BowShelf
Measure, Cut and Fit a Bow Shelf
(from 12" Board)
It Fits around the Stem
and under the Gunwales
Attach by Screwing it from the
Bottom up into the Gunwales
CONTENTS

12: Tauts & Rails
midShips Taut Rail Taut Rail
Rip about 20' of 1/2" x 2" Stripping from 2 x 4
Attach the Strips at 4" below the Gunwale
Attach a 12" piece of 1" x 2"Strip
to the midShips Rails as Attachment surfaces
for the midShips Taut.
NOTE:
Having the Taut Lower makes the Pond Boat
More Stable in the Water.
Fit the Rails accordingly.
Cut, Fit and Attach a Piece of 12" Board
to the midShips Rail
(The Ends of the Board Curve to Match
the Plank Curve)
Plane the Top Edges of the Taut
Use a Bar Clamp to hold the Taut Firmly
to the Planking.
STERN Taut
Cut, Fit and Attach a Piece of 12" Board
to the STERN Rail
Plane the Top Edge of the Taut
CONTENTS

13: Keel Strips
BowShelf BowShelf
Attach a Strip to the Bow
Cut a Strip from Scrap PlyWood
(Dave used Scrap LexonType Material)
Attach a Center Strip to the Bottom
You can Add more Strips, if you like

BoatFinished5 PL Cement VinylSeat
PL Premium Seals/WaterProofs the Pond Boat
Apply a Bead of PL Premium to Every Join on the Boat
Option: PlyWood/Foam/Vinyl Seat on Taut
CONTENTS

14: Paint
Grey Paint Paint Inside
Use an Epoxy Paint for the Interior
Follow Instructions on the Cans
Dave used BattleShip Grey Epoxy Paint
on the Inside
Alternatively, you could use Marine Paint on the Interior too.
(The Pond Boat is already Sealed by PL Premium)
Marine Green Green Paint
Use a Marine Grade Paint on the OutSide
Dave used Green Marine Paint on the
Tauts, Rails and Bow Shelf too.
Green Hull
The Trim is Painted using a
White FiberGlass Epoxy Paint
(NOTE: Marine Paint can be used)

CAUTION:
Part of the Reason for Painting a Pond Boat Green
is to Hide the Pond Boat near a Favorite Pond.
Dave's Brother said that he Painted his Pond Boat
in a Camoflage Pattern and he
hasn't seen his Pond Boat since!!
DO NOT PAINT THE POND BOAT
IN A CAMOFLAGE PATTERN!!!
CONTENTS


15: Oars
OarA OarC
6' Long Oar
An Oar is made from a Piece of 6" Board
and 2 Strips of 2" x 4' PlyWood
The Board is First Shaped into the
Rough Shape of an Oar
Attach a Strip of PlyWood
to each side of the Oar Handle
(Seal with PL Premium)
Placement of the Strips
on the Board
OarE Oar H
Clamp the Ends of the Handle
Attach Several more Clamps
Leave Clamped OverNight
Oar I Oar F
Use a SpokeShave
(or a Plane)
for the Handle's Rough Shaping
Use a Hand Plane
for the More Fine Shaping.
OarJ
Use a Knife
for the Handle's Fine Shaping
Oars Paint  Oar
Sanding is the Final Shaping Method
A Finished Handle should be Very Smoothe
Paint the Oar with Marine Paint
(Dave used Epoxy Paint on the Handle)

OarLockLine OarLock
Fit and Attach a Piece of Board
to the Gunwale
Drill a Hole Down through the Board,
where you want the OarLock to be
Tie a Piece of Line
through the Hole in the OarLock Base
Tie the OarLock (through the Hole) to the Rail
Alternatively, you could install
Dowels (Dildo Posts) as OarLocks.
Install 2 per Side.
They Extend (and are Attached) to
the Rail and/or to the BackBoard.
CONTENTS

Trouting/Fishing Supplies
Fishes Wishes, BlakeTown

Evening Shade
Don't Leave Home
without
'Evening Shade',
Dave !!

HAPPY TROUTIN'!!!
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