Building the Jack Tar       
   By Gary Zwissler
 

BACKGROUND
 

     After 13 years of owning and operating boats, reading and studying
     boat design and construction, and picking up a Coast Guard Masters
     License, I decided it was time to "take the plunge" - build a custom
     boat, just for me.  I had decided on wood construction for several
     reasons, including (in no particular order):
     
      •  Modern wood/epoxy construction is strong, low maintenance,
               and  is easily repaired
       
      • Materials are readily available
       
      • I had the skills and tools to do the work
       
      • Wood floats (always a nice thing in a boat)
       
      • Literature and plans are readily available
       
      • I like wood
       
      • My wife likes wood
       
    Next I had to select a design.  I selected a Maine lobster boat for several reasons:
     
      • Sea worthiness
       
      • Sea kindliness
       
      • Affordable operation
       
      • Maximum deck space
       
      • Trailerable
       
      • Affordable construction
       
      • Classic looks
       
       
    Now the choice was what kind of wood construction.  For my skill level
    and pocket book I wanted to use plywood.  At the time, by coincidence,
    National Fisherman magazine published an article by Arch Davis
    describing a 26' plywood Maine lobster boat he had designed.  In
    September 1993 I contacted Arch and was on my way.
     
     
CONSTRUCTION
    I started construction in October, 1993.  Since then I've worked on
    the boat on weekends, holidays, after work, rain or shine.  I'm
    closing in on a launch date during summer, 1998.  I've done several
    things that expanded the scope of the project, such as: building a 2
    piece 5/8" laminated bottom, transom door, fiberglassing the bilge,
    and fiberglassing all wood exposed to the elements.  A bit extreme? -
    perhaps.  What can I say?...its MY boat.
     
THE DESIGNER AND THE PLANS
 
    I opted to buy full-sized templates from Arch.  These were a godsend.
    The purist would say to loft the boat from the lines plan - been
    there, done that.  When you are committing to a 4 year, $20,000
    project, you have to get it right the first time.  One hundred bucks
    for accurate templates (on mylar!) is cheap insurance.
     
    I've followed Arch's plans religiously.  The result: an accuracy of +
    or - 1/8" through out the building of the entire hull, deck, and
    sides.  I often make a template for a starboard fitting and can use it
    for the port fitting as well.  Arch's design accuracy is fantastic.
    You can actually build what he designs.
     
    Arch is very helpful, always available to answer questions.  On
    several occasions he has patiently helped me through my ignorance.
    For instance...the time I called him at 10:00 PM (his time) and in a
    panic described how I'd used the wrong epoxy filler for a lamination.
    He advised me to make a test piece, duplicating the lamination, and
    destructively test it.  I did.  It broke well into the wood, proving
    the joint strong - crisis resolved.
     
THE TRAILER
 
    Six months of my construction time was spent building a trailer for
    the boat.  The trailer also acts as the cradle after the hull is
    turned right-side-up.  I designed the trailer using the hull plans.
    Its specs are 32' long, 3 axles, 15,000 lb capacity.  Once again
    Arch's design accuracy was proven.  Final height of the trailer bunks
    was within 1/4" of expected.
     
CURRENT WORK
 
    I'm currently building the trunk cabin, pilot house, and interior.
    Next will be the electrical systems and electronics.  As I get further
    along I'll post new pictures of my progress.
     
ADVICE FOR OTHERS
 
    Boat building is a great way to relax.  Its one of the few areas in
    your life that you get to be totally in charge.  Don't rush, enjoy and
    learn.  If your new to this, plan your schedule by estimating the
    project time, then multiply by three.  I started out estimating
    project completion in hours, then days, then months.  Now I estimate
    by seasons and I'm having a great time.
     
    For those of you who are married, the most important thing you can
    have is an understanding spouse.  Your project will demand much of
    your time (if you ever want to get it done).  Attempt to get your
    spouse involved in your project, but don't demand it, or be
    disappointed if they choose not to.
     
    Don't be afraid to make mistakes.  Often its the best, if not only way
    to learn.  Learn from your mistakes.  Fail forward faster.
     
    Don't skimp on materials, but don't go overboard either.  Sure you can
    use okume plywood for the cabin sides, but A/B doug fir works fine
    (especially if you fiberglass it).  Save your marine plywood for the
    hull.  Also, add some nice touches that will set your project apart.
    For me that means all bronze hardware.  Yes its more bucks, but after
    all...it's MY boat.