Paul Gager Builds an Original 1956 Ace
Paul Gager of New Jersey had already built an 8 foot dingy and a 16' sailboat. He looked at a few old copies of the Boat Builder's Handbook and then found Svenson's web site where the Ace plans from a 1956 Handbook are available. This was what he was looking for; plywood on frame construction, not too big, not many frames, not overly complicated, and it was similar to the type of boat his family had owned in his youth.
Paul drew the plans full size in his basement and started construction. Due to the change in lumber sizes over the years (a 2x is no longer 1-5/8" thick; nor is a 4x 3-5/8"), adjustments were necessary in stringer sizes.
Paul cut some trial framing from pine boards to see how everything would fit together.
He laid out the frames full size using a roll of brown building paper and a lofting table made from two sheets of plywood.
Here's the trial fit of the forward frame, rim pieces and stem. Everything fit after a little adjustment.
After all the frames were glued up and a major pieces were cut out, Paul clamped everything together to see how it fit. He found that the transom knees did not align properly and had to be adjusted. You can see were he modified the bottom framing, adding two more bilge battens on each side. The #2 frame was also modified from the original plans but the bottom contours were kept as original.
The framing was fastened together.
When the chines were installed the first time, they broke at the #1 frame when left overnight. Paul laminated them from two pieces of stock needing almost 50 clamps! It's tougher to get good lumber now than it was in the 50s and 60s.
Paul's neighbor takes a look at the completed frame.
Paul checked the fairing of the bilge battens with a strip of 1/4" plywood as a batten.
A cardboard pattern was used to fit the forward bottom plywood.
3/8" Philippine mahogany marine plywood was used on the bottom.
1/4" Mahogany plywood was used on the chines after packing the frames, transom and chines with 1/8" strips of wood to make sure everything fit correctly.
Three rachet straps were needed to pull the aft side planking into shape at the transom.
All of the screw heads were filled with epoxy fairing compound.
Here we see the transom tumblehome and "non-trip chines."
Although the plywood has not yet been trimmed along the gunwales, sanding the epoxy essentially completed the planking!!
Right side up and looking good!
Fall 2007 has arrived. Paul is looking forward to finishing the Ace this Winter and launching it in the Spring.