Inside the pack were four and a half sheets of 6mm ply. Each sheet had been CNC cut with the pieces held in the sheet with short tabs. Here are the four full sheets - you can enlarge the photos by double clicking on them.
First job was to laminate the 3 layers of 6mm ply that form the inner stem. Where the pieces join there is aan individual puzzle joint so the pieces can only be assembled in the correct order. Here they are wrapped around the mold with plastic to stop them sticking to the mold and plenty of clamps.
While the epoxy was setting on the stem I laminated the five pieces that make up one of the outrigger arms. There are 3 pieces of 6mm ply with outer layers of 4mm solid timber. The laminations are kept in place by the bolt at the left hand end of the jig. With this pulled tight the clamps are applied progressively to the right.
Here is the complete lamination held in a pipe clamp to stop (or reduce) springback until the epoxy is hard.
The rest of the keel is made up of 2 layers of 6mm ply put together in sections and glued with epoxy. No photo of that but essentially the same as the stem. Once the stem and keel are glued (and screwed to the mold) the edges have to be bevelled so the first plank can be glued to them. I did this with a Ryobi cordless planer fitted with an arm the outside of which is in line with the base of the plane.By running the arm along the lower stringer (where the plank will sit the plane is held at the correct angle for the bevel.
Here are the pair of outrigger arms after some initial cleanup. When in the boat the oarlocks will be in the hole at the rounded end, the far ends are joined together at the keel and the mid point is bolted to the gunwale.
Next step is to make the transom, fit it to the mold and glue it to the end of the inner keel. While that glue is setting the aft end of the garboard planks has to be prepared.
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