Mortises and More Mortises

In the last few weeks I’ve shaped and sanded my gunwales, plus drilled a boat load of square holes.  Forty four blind mortises and twenty two standard mortises, at three holes per mortise it was a lot of drilling. 

Drilling all those mortises really wasn’t has hard as you would think.  Thankfully the book I am using lays out the steps and with a little patients, which I normally lack, I had some rather nice holes.  Laying out the mortises, I think, is the most critical step.  On the blind mortises, mortises that are ¾“ deep and you can’t see through, I laid out how long the mortises should be but not the width.  I relied on my drill press to center the holes.  The problem with this is I’m not using a mortising machine, the drill press I have is a device that turns a hand drill into a drill press.  As you can see in the photos it looks older than dirt, because it is.  It was given to me by my dad and I remember him using it with his hand drill when I was pretty young, so the thing is 35 to 40 years old.  Making an alignment jig helps but if you have all four sides laid out it would be much easier to make sure your overlapping hole used to create the final product are all in line.  I also bought a new chisel and kept it extremely sharp.  I would suggest if you are doing this project and you aren’t very good at sharpening you find someone to teach you.  A really sharp chisel makes creating the square corners an easy job.

Once the rib mortises were done it was time to shape the top of the gunwales.  The forward and aft ends get a shallow curve that extends 70” down the top.  I laid these out with a batten, also know as a tent pole, then cut and planed up to the line.  In the book I have Chris Cunningham shows’ using a block attached to the side of the plane to make sure everything is kept at a 90 degree angle.  The plane I have is pretty small and I could not clamp a block to the side so I just took it slow and checked my work often with a square and had no problems.  Once the gunwales are shaped it was time to drill the deck beam mortises which are at a 73 degree angle a very intimidating task.

Laying out the mortises for the deck beam was pretty easy with a jig I created.  As you can see in the photo that I made a square hole that was 3/8 x 1 1/2, I then drew a line 1 ¼” from the opposite side.  Since my mortise was going to be 1 1/4 “ long I could simply align the line on the jig with the line laid out for my deck beam mortise and draw the other three sides of the mortise.  This along with a jig to hold my gunwale at a 73 degree angle made drilling the holes for the mortises much less intimidating.  Cleaning out and squaring up the mortises was done pretty quickly with a four in hand wood rasp and a square cabinet maker’s file.  Good luck finding a square file if you don’t have access to one.  I was going to buy one and I checked Rockler, Woodcraft, and Lee Valley with no luck.  A quick call to my Dad and he dug through his mountain of old woodworking tools and found two of them.  I don’t think the square file is essential but does make squaring up the corners a breeze.  If you are thinking about starting your own boat I would start looking through garage and estate sales to find one or maybe you can find a better source than I could.

The final steps to the gunwales are beveling the top edge, which I screwed up, and beveling the tips.  I didn’t reread the book and beveled the wrong edge on gunwale.  I don’t think this is going to be a problem I will just have some weird angles to cut on my arched deck beam that align with the bottom of the mortise not the top like the straight ones.

Now that the gunwales are done it is time for the deck beams.  Today it is raining and cold so that means it is a perfect time to go dig through the stacks of lumber at Menards.  No one else is stupid enough to be out there.  Since I will need to rip and plane the boards outside I will have to wait until the rain stops to get everything ready.  With Christmas fast approaching the deck beams may have to wait until after the holidays.