Building the "Swiss Army Knife" of Small Boats...Wood Duck Double (WDD) #8: Beveling the Panel Edges

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Blog entry by DustyMark posted 06-26-2020 03:27 AM 323 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 7: Gluing the Puzzle Joints Part 8 of Building the "Swiss Army Knife" of Small Boats...Wood Duck Double (WDD) series Part 9: Stitching the Hull Together »

Back to the Boat
I installed a suspended ceiling and finished wiring the lights and switches in my finished basement project and also took a week vacation to Madeline Island in Lake Superior since last working on the kayak. I’m finally working on it a little bit between fishing and camping trips…I love summer in MN!

Sharpening a Block Plane Blade with a Tormek Sharpener
Beveling edges cleanly on thin mahogany plywood is best done with a sharp plane. My block plane blade was dull from a previous “abusive” project.

I’ve used a Tormek water sharpening system for years. I like the slow, controlled grinding process that puts on a fine edge quite accurately. The accuracy comes from expensive jigs, but the investment does pay dividends in a shop full of sharp tools. I established a 25 degree bevel for this project.

Removing the burr with a fine diamond stone.

Establishing a fine bevel with the same stone by hand.

Here’s the edge after fine honing on the diamond stone. I touched up the blade with four strokes using this method after completing two edges on two panels. That’s about 60 feet of beveling, including crossing the cured fiberglass in four areas. This is only a Stanley block plane with a very shallow bevel and it doesn’t hold up much more than that for a good cut anyways.

Beveling Process
Most of the panel edges are beveled to 45 degrees. This provides a place to apply thickened glued where the panels meet. The bow and stern are beveled to a shallower angle as they come together at a fine point.

The plywood planes down quickly with a sharp blade. The idea is to be smooth and not ruin the flowing curves of the panels as you bevel them.

Shallower bevel at the bow.

Front edge of side panel.

Deck panel.

Deck panel that transitions from a bevel to no bevel.

Stitching the hull together.

-- Mark, Minnesota

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