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Finally got back on this project! I cut the gunwales out of Luan mahogany - 3/8" x 3/4". Sanded both sides and cut the scupper blocks per the book. I glued on the scupper blocks (epoxy and colloidal silca), but didn't use enough of the thickening powder - kind of a challenge!
After overnight curing, sanded all sides and ran it through a 1/8 roundover bit on the router table. Didn't do a very good job on the inside corners of the blocks, but not too bad for a first effort. I'll try the Forstner bit method next canoe.
I then glued (epoxy and colloidal silica again) the block side (inwales) to the interior and clamped. I did use enough colloidal silica this time - consistency of peanut butter, per the book. Had to borrow some clamps, however.
Lastly, glued the outwales on, same as inwales. Next is sanding
What would I do different?
I'd use 1/4" blocks and strips instead of 3/8" for the gunwales. I think they'd be plenty strong enough, and would look better (same thickness as the canoe).
I'd also glue temporary locating block on the inside of the canoe to get the inwale points all at the right height. I ended up sanding down the gunwales to quite a bit less than 3/4" to get them even.
Round the ends of each block - either drill or 1/4 groove the short way.
Only round the bottom of the gunwales. Round the tops after it's glued on to the canoe and sanded down.
This is the state of construction as of July 1, 2006.
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