After three sailboats, I decided it was time to try something different -- a stinkpot -- in this case a 19' 9" Albury Runabout outboard. This boat originally built by sight by the Albury Brothers in the Abacos Islands in the Bahamas for the purpose of working among the islands. It has gained a solid reputation as a well built all around small utility outboard. The boats were all originally made of heavy local woods, but that was changed to fiberglass in the 60's/70's. Today, they are still made of in several different sizes.
Twenty some years ago Doug Hylan of Maine visited the brothers in the Bahamas and got permission to draw up the basic hull and publish the plans for sale through the Wooden Boat store which is where I got them and where I got the plans for the sailboats I have built. Unlike the sailboat plans, these plans did not contain plans for the molds. Therefore, I needed to spend some time figuring out how to loft enough of the plans to be able create plans for the molds myself. I have finally completed that and now have the molds in place on a building frame. Those molds and frame are shown below.
To my knowledge all of these boats have been built with carvel planking and the plans call for that. My plan is to build it with epoxy plywood lapstrake planking as I did on the three sailboats. That decision has led to some indecision about what thickness of plywood I should use for this build. The three sailboats were 1/4" and 3/8" planked and the heaviest boat, the Caledonia Yawl weighed around 600#. The designed displacement for this outboard in 2400# which means everything about this boat is much heavier than the very light sailboats. Recently, I had been thinking that the plywood will be between 1/2" and 3/4" and, after speaking to Doug Hylan, finally decided on 5/8".
Getting what I figured to be 13 planks on a side or 26 planks altogether turns out to be quite a project. Each plank takes me several days. It starts with scarfing together at least three sections of 8' plywood in order to cover the length of the boat and cutting these in a way which both conserves very expensive marine plywood and still covers the length of a 20' boat. Once the plank has been spiled and cut to size, it needs to be chamfered on two lengthwise edges and gains cut on two edges at each end. It must also be used as a pattern to cut its opposite side plank. Then it must be dry-fitted to see that everything goes where it is supposed to and fits everywhere. Finally it can be glued and clamped.
I have just completed the final 26th sheer plank. All were bent around the hull without steaming. I was sure some of them might snap, but didn't want to chance compromising the scarfs by steaming them. As it turned out to my surprise, none of them snapped -- even the solid ash sheer planks. I am beginning to worry about how heavy this thing is and is going to be in the future. Right now I estimate that the fully planked hull is right around 600#. That is only one quarter of the final 2400# displacement. It is yet to be turned over as it all has to be sanded, a splash rail developed and attached and then sealed with epoxy, painted and finished.