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Zazzle is a step beyond. Beyond what? Anything Im likely to do.
The more books about lofting and clinker construction I read the more ambitious my own project seems. But for Nigel Sabin that wasnt enough. As well as building in clinker he chose to use wooden fastenings: trunnels or tree nails.
Nigel built Zazzle while at the Lyme Regis Boatbuilding Academy; a school that haunts my daydreams.
Planking Timber 2
I cut a piece 6" long and about 5 inches wide from each board and then resawed them to the thickness of the thinnest, the Yellow Cedar, at half an inch. The Sitka Spruce is a much narrower plank than the rest but I think I can account for that in this next stage of testing.
I wanted to find out which split the least when nailing planks together. I started by drilling pilot holes and then hammering in progressively larger nails. Its good to know that this resulted in almost no splitting and eventually I had used my biggest nails.
To get a result I then tried hammering nails in without pilot holes close to the end of the planks. I started at 20mm from the end and 20mm from the nearest edge.
Western Red Cedar was the only board to split.
Then I moved the nails further into the board and closer to the end.
Sitka Spruce and Douglas Fir went next at 10mm from the end of the board.
Yellow Cedar and Khaya Mahogany didnt split even at 5mm from the end of the board though the Yellow Cedar did produce a lot of tear out.
The Douglas Fir and Sitka Spruce seemed the easiest to hammer into and pull nails out of. Next was the Western Red Cedar and then the Yellow Cedar. However to say these were "harder" to nail into is not to say they were "hard". It was all very relaxing.
The Khaya took a bit more effort on the way in but clung on for grim death on the way out. The only nails that bent on exit left this board.
Yellow Cedar is definitely winning. I was trying not to admit to myself that I liked the idea of using Sitka Spruce. Its a very pale colour, which is my preference, and the strength to weight ratio would make a very light boat. Now that Ive done some testing Im sold on the Yellow Cedar.
When I get some Oak Ill compare it with the Khaya. Gartside shows it as an alternative choice and I can certainly get enough domestic oak to salve my conscience.
The mahogany is so good to use the thought of building the whole boat from it has crossed my mind.
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Douglas Brooks on Sabanis
I am in Iejima, Japan, a small island that is part of Okinawa, building an eight meter sabani, working with one of the last three builders of these indigenous fishing boats. This work is supported by the Center for Wooden Boats in Seattle, the Asian Cultural Council in New York and the Nippon Foundation in Tokyo. This is my fifth apprenticeship building Japanese boats.
I will keep my comments below very general as the point is to get the reader to go through my blog, where you will find more detail on history, culture, construction techniques, etc.
The sabani is what we would call a semi-dugout type, and in that respect it shares a story with many similar types around the world. As the Okinawans deforested these islands the timber required to make dugout canoes became increasingly difficult to find, hence the move toward a plank-built boat that still retains some of the characteristics of the dugout. So the boat we are building has a four inch thick bottom that we have shaped from three timbers, joined together with butterfly keys and bamboo nails.
Bob made a very interesting observation that sabani are built upside down, with the side planking first, and then the dugout bottom dropped on top. This is opposite of any semi-dugout traditions that either of us know, which start with the hollowed bottom and then add the side planks. Its also odd given that throughout the rest of Japan its absolute law that boats are built right side up. I will try to ask my teacher what he thinks of this.
Most of the techniques are familiar to me from my other work in Japan, but I wanted to study sabani in part because of the fastening techniques. I already have several blog posts up about the huundu, or dovetail keys, so I wont belabor that here. There will be more postings to come as we continue to use these fastenings to assemble the boat. I am certain that they are a holdover from the days of dugouts, and iron fastenings would have initially been very expensive. I am also finding that while we install them using only hand tools, it is not a slow process, so it all makes good sense, even today.
There are other dugout and semi-dugout traditions in Japan, particularly in the far north, where some still survive. In the mid-90s I met the last dugout builder of Akita Prefecture. He was still fishing every day in a dugout he built in 1965 and he had just built his last dugout as part of a documentary project. On the coast of Akita, Aomori and in Hokkaido you can still find semi-dugout boats in small fishing ports. The first photo shows fishermen out on a winter day in 1965 in their hatahatabune. ("Hatahata" are a small fish, "bune" means boat.) You can just make out the dovetails keys in the bottom, which in a boat this size is six to nine inches thick [Bob here: note too the interesting handles on the oars.]
The next photo is an isobune which means inshore boat. These are still fairly common on the Aomori coast. The bottom is a single timber hollowed out, with a stem, transom, single frame and plank sides added. My teacher in Aomori told me that during his apprenticeship most of his work involved hollowing bottoms of isobune (he quit after three years of this unpaid work).
Back to Bob now. I recommend Douglass blog -- good photos and good writing, with interesting observations on the apprentice system and other aspects of culture in Japan.
A few more items that Douglas noted in our correspondence:
- The side planks of the sabani shown under construction in his blog are not standard milled lumber. "Dont let those side planks fool you, they are CARVED. We started with 2+" thick planks and hollowed about half of the volume out of them on the inside, leaving material for thwart risers and left full thickness at the stem and transom."
- On the dugout-style bottom: "My teacher has specifically talked about the thick bottoms as giving these boats their stability. I have roughly calculated that the bottom alone (its long and very narrow) represents between 40-50% of the weight of the entire boat."
- And regarding my earlier post on sabanis, which stated that the helmsman sits in the front of the boat: "I suspect is a mistake made by the Japanese writer. It just doesnt make any sense at all. And I have yet to see a sabani or harebune with a helmsman forward. By the way, those festival boats are not strictly speaking sabani, at least not today. They are plank built and considered different from sabani among the old-timers."
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Yesterday I received the latest photos from the owner builder, taken this past weekend. When you look at them, please bear in mind that this man is an amateur boatbuilder and this is his first ever boatbuilding project. He has been a very hesitant builder, unsure of his own woodworking skills being up to the task that he had taken on. He has occasionally needed my reassurance to guide him in the right direction or confirmation that he is doing something correctly. He has shown himself to be a meticulous craftsman, working to a higher degree of accuracy than I have in any of my boatbuilding projects.
As you can see, his boat is looking absolutely gorgeous. He is producing a boat that is a work of art and of which he will feel very proud, justifiably so. I look forward to sailing this boat and seeing it exhibited at Mystic in 2013.
The builder is Aussie Hunter Gall. He lives in Virginia Beach, Virginia but is building his boat at a friends property in Elizabeth City, North Carolina.
You will not find this design on my website yet but it should be there soon. The tentative design name is the DS15, for Didi Sportboat 15. It is 4.5m (14 9") long and 1.8m (5 11") beam.
You can see our other designs at http://google.com/
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