This is the project that invariably gets a marked reaction from people. What would cause an otherwise reasonable person to want to build a large boat, and why would so many people feel strongly that it is a great/wierd/crazy/inspiring thing to attempt? I do not know the answer to that question, but I will probably get some hints along the path. I view it as a process consisting of a long string of small steps, with the trek being as much fun as the goal.

This most recent flash of creative juice started a couple of years ago after reading a detailed book about how sailing yachts are designed. To be fair, though, I owned part of a sailboat 30 years ago while living in California. So, I can honestly say I have thought about this for a long time. Reading a few more books about sailing vessels had me convinced that a steel-hulled cutter would be the ultimate boat for secure cruising in blue water.

After trying to balance a million conflicting parameters, I finally bought the cutting files for a Spray replica from Bruce Roberts Design – a Spray 370C. This has the elements most important to me and is small enough to extract from our back yard to move to the ocean. I want to integrate this project into my life so that I am at home with my family when tinkering.

Sept 2004 – Here is the building site with 6 pier blocks set into the ground for supporting the bedlogs.

Dec 2004 – With steel prices so high, I found some free steel to use for the work supports.

Mar 2005 – I took the center pieces from the scrap frames and built these steel sawhorses. They will form a level base on which to section the longer 20' beams.

Oct 2006 – The resulting 20' beams were not good enough to use for bedlogs, but they made a dandy A-frame gantry.

Oct 2006 – These concrete slabs will support the steel work jigs.

Dec 2006 – Delivery of the steel parts from the local steel distributor. If you are expected to unload this much stuff, you will need a construction forklift. Sorting steel plates in the driveway. The goal is to build a craft like this.

Mar 2007 – Built the caster and track assemblies for the gantry frame. It glides on the tracks easily, and using v-groove wheels and inverted angle gives a self-cleaning track.

May 2007 – Finishing the canopy frame has been a lot of ladder work with the stick welder. Covering this with a tarp will give a nice workspace.

June 2007 – Finally covered the canopy with a tarp that is incredibly tough (used billboard vinyl). Time to build a boat!

July 2007 – Began tack-welding the sides of the keel with this jig that ensures an exact match of the curvature (since this helps set the shape of the hull).

Aug 2007 – Moving a keel side into place inside the support jigs. Note the rigging to keep from snapping the tack welds.

Oct 2007 – The completed keel positioned inside of the work supports. The weather is now more of a challenge; I am always looking for dry workspace big enough to assemble boat parts. I knew this would be a difficult worksite, but sometimes I dream of that 60' by 100' heated warehouse.

April 2008 – The belly plates are now in position ready to be tacked to the keel, and many of the frames are ready to be set upright into the resulting assembly. I'm very happy with the performance of the gantry crane, as the large plates could be placed by one person.