The Lumberyard
Placing beams 4-9 (click to open/close)
After beams 4 and 5 which hold the forward mast partners are in pace and beams 8 and 9 which hold the capstan base have been placed in the hull, we will now place beams 6 and 7. First, measuring sticks are used in the location where the beams will fall. When the length of the beams are determined the measurement is transferred to the beams and they are cut to length.
Placing temporary lodging knees (click to open/close)
The three lodging knees are temporarily put into place between the beams to check for fit. Rubber bands were used to hold the beams and knees in place.
Trimming knees (click to open/close)
Taking a close look it is apparent beams 6 and 7 plus the 3 knees are slightly too large to fit the area between beams 5 and 8. Not all of the extra material was taken off one knee, this may result in the carlings not fitting properly. Just a little was taken off each knee until the beams and knees fit in the allotted space.
Hanging knee notch is cut (click to open/close)

Each knee was clamped in a vice and the notch for the hanging knee is cut out using a fine tooth razor saw.
Lodging knee glued in place (click to open/close)
When the knee is cleaned of the laser soot and the hanging knee notch is cut, the lodging knee is glued in place.
Soot removal and sanding of knee (click to open/close)
To clean the soot off the knees they are placed in a vice. Once held in place a file is used to remove the majority of the soot. A little touch up with sand paper and finally a little scraping with a razor blade or exacto knife will finish the knee.
Examine hanging and lodging knees (click to open/close)
Here is a view of the hanging and lodging knees in place and ready for deck beam 6.
Placing beams in hull (click to open/close)
Deck beam number 6 is cleaned up on all four sides and placed in the hull. Small C-clamps are used to hold the beam tight to the side of the hanging knee. Before the final placement of the beam, lay all the carlings in place. This is done to insure the carlings will sit square to the beams. The deck clamps are wide enough to allow a little play in moving the beams from side to side. When trimming the beams to fit the hull allow a little side to side movement for minor adjustments in lining up the carlings.
Examine placed knees and beams (click to open/close)
The knees and beam number 6 are now in place. The knees are set slightly above the deck beam. This is done because the beam has a curve to it and the knees will be sanded to match the curve when the deck is given the final sanding.
Fitting other knees and beams (click to open/close)
The same steps for beam 7 are followed for the fitting of the knees as was done for beam 6. Once again using the carlings to make sure they sit square to the beams. Once all the knees and beam 7 are checked for fit they are glued into place. At this phase of building little globs of epoxy that squeezed out of the joints is of no real concern. Once the entire deck is built it will be given a final sanding and finish. The epoxy is easily sanded away.

Go to part 16- DECK CONSTRUCTION 2

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