Trimming Frame Members

Now that I have the lumber for the frame members cut to rough shape with a corresponding router template for each part, it’s time to trim them to final shape. I setup the router in its table with a template bit beforehand. This is also my first time using a template bit.

I used screws to hold the 1/4” MDF templates to the boards so they wouldn’t move. I tried to locate the screws so the holes will be hidden under the gussets. 


I trimmed each board on the band saw so it was slightly larger than the template (1/16” or so on each side). I then went to the router table and used the push handle to move the wood clockwise across the router bit. It took a little while to get the hang of which side of the wood to put the template on so the cut would follow the grain to prevent chipping, but I eventually figured it out. 

I really liked this method of making parts. They came out very smooth (barely need sanding) and exactly to shape.

After trimming the parts, I was very happy with how closely they matched the plans. 


I did some more tracing to make a full size pattern of each of the five frames. The plans only have full size patterns of the right (starboard) half of each frame. I had to mirror the patterns across the center line to trace a pattern of the left (port) half of each frame. I was very careful to line up the halves but am still a little worried if I got it close enough. 

With the parts laid out on the patterns, I really feel like I’m starting to make progress.  I almost have a boat kit ready to start assembling!

Next step is to assemble the frames. All joints will have plywood gussets that will be epoxied and nailed in place.  But first, I have to wait for the plywood and silicon bronze fasteners to come in. 

I couldn’t find any 1/4” marine plywood locally, but after some searching found some in Canada. The best part is they have a warehouse an hour away so no delivery charge (which is very expensive for 4’x8’ plywood sheets). I ordered: 
  • 4 sheets of 1/4” okoume for the hull
  • 1 sheet of 1/4” okoume  for the centerboard case and gussets
  • 2 sheets of 1/4” Sapele for the deck. 
I was very happy I could find it within driving distance. 

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