The jig is up [S4E14]

[Music] have you ever completed a huge project wow only to later discover that your entire process was flawed [Music] that's what happens to us in this episode join us as we make a few mistakes [Music] uh [Music] [Music] so [Music] um [Music] so what have we got going on here i'm trying to make a lamination jig for our new deck beams our new deck beams that's a phrase i'm going to have to get used to ever since realizing just how far gone most of our deck beams are we've had to resign ourselves to a big new chapter in this refit the replacement of the deck beams and the first step is to make a jig no not the irish kind unfortunately a jig is a curved mold if you will the curve of our jig has to exactly match the curve of our deck beams our deck beams are going to be made out of four layers of cedar glued together with epoxy the process is to glue the layers together then clamp them all down on the jig so that they dry with the correct arc then voila a curved deck beam is born but now the tricky part is in measuring the exact curvature of the existing deck beams so that we can make an accurate jig so these beams they actually look pretty straight but they're not they have a very slight curvature to them i keep referring to it as crown on some boats the curvature changes as the width of the boat changes or yeah it just doesn't have to be the same curvature everywhere but it is to my eye at least very consistent very consistent in the cape george boats there's the same curvature in the cockpit on the side decks and over the bow so the first step is figuring out how much that curvature is so how did i figure that out well one initial simple method was measuring so to measure we'll have two rulers yeah and this one is about the length of a beam so that's perfect because then i can have the edges kind of sit here and then i peek over the top because there should be a hollow if the beam is curved and then with this one i measure and this is actually very accurate it goes down to 60 fourths of an inch so here we go well this is not the best example as the trim is interfering here slightly but you get the idea and then i hold this one up here and it measures a teeny weeny something of a little bit well at least we know this is going to be accurate after this i proceeded to kind of get confirmation and i did two additional things and now the first one was string a line but i did so where i have a full beam so why don't we go up there and i can show you what i mean so here is our beam that goes from side to side and you can perfectly see the curvature to the beam so now i've attached a string and now i can go to the to the middle where the arc is the highest and i measured again here and i came to discover that it is an inch and a half on a eight foot arc width okay and i mean technically you should be measuring right in the middle right but yeah oh did you measure that exactly yeah totally oh it is centered again another thing that you can do then to reconfirm it is split this eight foot section into two foot sections which are equal to the other beams and i did so by just holding up the string now this would be a four foot section from zero to zero arc width and then i can measure here in the middle or i can divide it once further by holding it just here and then i have again only a two foot section which are the short beams and then if i measure the little gap that i have here i have the height uh within well whatever arc width right because that height should be the same as the one you just measured out in the saloon exactly and it is right and it is it is a something of a something it is yeah over 64 uh now it is um roughly two to three 30 seconds so it's tiny i also took a sheet of paper i tried to do some math and i try to get inspired by michelangelo but it didn't work but what helped me was a website that i found along the way it confirmed these numbers so that's pretty cool so the website that i found you can put in two numbers two variables and you get a third the two numbers that i had were the arc width and the height that is eight feet and one inch and a half or two feet and three two to three thirty seconds and the third variable that it spits out is the radius pretty much those numbers that i was able to read off this tiny thing confirmed the same radius a radius of what is it 768 inches and three quarter so pretty huge radius but the very very handy thing of this website is that then you can divide this whatever section you want you can divide it into one inch increments or five and i chose six and it shows you from the bottom line going up towards the curvature how big the distance is at a six inch interval so then i basically had so then it was pretty easy to me to draw a line and measure and then draw an arc on the table okay so let me recap what's happened aladino measured our deck beams using rulers and a string he determined the height of the crown and the width of the arc with those two numbers he could then figure out the radius of our deck beams using a calculator on this website fortunately the radius for the shorter beams in the saloon turns out to be the same as for the longer beams up forward which is good news for us as it means that all our deck beams have the same curvature but how does a radius help us well with a radius you can find the circumference and an arc is basically just a chunk of a circumference so say we need to make a six foot beam this is where that website comes in handy again you can type in that you need a six foot beam and then the website will use the circumference of the overall circle basically just remove a six foot chunk and then it will analyze that chunk to tell you how high your crown has to be the website can also tell you the height of the arc at any interval you need not just at the crown so say you want to know the height of the arc at every six inches of your six foot beam the website can do that for you so that's what we did we wanted to make an eight foot jig since that's the longest beam we'll have to make and we wanted measurements at every six inch interval just to make sure we were drawing the curve right once we had those measurements we could mark it all on a piece of plywood and then cut it out to make our jig [Music] so [Music] yeah 50 so this should do because now running the router here we should come close to zero here in the middle here that looks pretty good to me okay and then we have exactly the same curvature to make the jig we needed two pieces of plywood with the exact same curve so aladino cut a second piece with a router using the first piece as a guide [Music] wow what holy crap it's just a test piece we don't even know if it works yet but um yeah but it looks mighty impressive it looks pretty sweet doesn't it well you were out here until about 1am last night and i went to bed because i was like this is enough of this so this is the first i've seen of this just overnight aladino had made a beautiful looking jig but like late night projects are often bound to do this one hadn't turned out perfectly there was one big flaw in his construction method although neither of us had realized it just yet as aladino explains his process in making this jig try to see if you can figure out what the flaw is so just to recap about the construction because i didn't have a game plan when i started it i had an idea and i it developed as i went my idea was i take the hole saw i caught holes into the plywood so that i can use the clamps but the clamp always needs to be supported about at the same level of where you actually clamp it down on top so as you can see this does not work properly this would only make the wood slide so because of that i added this two by six so that i have half an inch or three 8 visible and it is a support it is a shelf for the clamp to be in the middle of the jig like so and then the pressure can be applied right in the middle and the very final touch was cutting some lumber into these little strips here and then i've just glued them on top as a base for every kind of wood that i would have on top so you may be shouting at the screen already if you've noticed what the big design flaw in our jig is but in case you haven't spotted it yet like us let me fill you in so aladino measured the curve of our deck beams and then transferred that exact curve to the plywood which he used to build the sides of the jig then he placed wooden spacers on top of the plywood sides since neither of us are particularly fond of or good at math we didn't think twice about adding these spacers they were all exactly the same size as each other so we figured they wouldn't change the arc they're just creating a parallel arc well we were wrong that's not how arcs work and by adding these spacers we actually changed the arc entirely i mean if you really think about it it makes perfect sense as the radius becomes bigger it's not the same arc anymore but i don't know my stubborn brain just looking at it was like well look at it it's so parallel it's got to be the same so i just drew out um two different radiuses here and then i made a little um plastic thingy let's say we are using the small radius right now so i place this one exactly over the small radius and now moving it up parallel to the upper one it reveals not a parallel gap anymore yeah it's a very different arc and the same thing instead if i place the plastic on the big one and i move it down to the smaller one then you can see ah not quite curvy enough we have uh accepted and realized our mistake yes um but i think we're on to something good now with the new jig [Music] but instead of completely rebuilding our jig we decided to just make it work by reshaping the spacers aladino planed some down and added wood to others all the while checking it against the original curvature it was kind of an anti-climactic finish but in the end we did have a jig with the right curvature to make some new deck beams and that was the important part basically in the end i i didn't want to do any more math and anything with numbers so i just relied on an existing beam this is one that i took out and i used this one to get the arc that i needed and i mean of course there was also some measuring know how much i was wrong in the first place so i had to rinse it here and lower it at the ends to get um a smaller radius more curvature and this original beam touches everywhere and slides along really nicely and you did make another test beam right yeah and one thing that i can say about that one is well i made it to be eight feet two but since i haven't opened up the decks yet to check um if this is correct and we learned i cannot set it on top of the decks to see if it's accurate because it will be different so therefore i have cut a short beam out of this long one i walked into the boat with this short beam and i could double check everywhere if it fits and how similar it is to the original beams and there is slight variances uh some are a little taller some are a little shorter but they all are within 99 of this arc uh this seems to do really really nicely awesome yeah the journey wasn't perfect but we had made it [Music] hey jaladino hey we got a delivery today didn't we you want to talk about it oh too glad we didn't film it but um was uh almost an underpant still well i was in bed when it knocked on the door i thought they would arrive later yeah they came at like 8 30 and we're not really early people yeah so there was the truck from edensoft our wood was being delivered we had ordered some alaska yellow cedar to make our new deck beams and it had just arrived now there was truly nothing between us and this next huge chapter of the refit [Music] yeah it's a very nice wood very straight grain uh no knots or one or two so next thing we'll be getting two smaller sizes i will use a friend's cabinet saw for that i think yay now also we got some plywood yeah so so this is for the deck beams exactly back beams uh floor timbers stuff like that and then the plywood you want to show that that's the plywood so excited about this i mean this is the most basic of boat building plywood plywoods to me okume plywood um it's still talking of mahogany plywoods it's a subspecies of mahogany it's not actually mahogany but everybody refers to it still isn't hagony mahogany mahogany mahogany yeah anyway i don't know but i'm doing okay between english and german otherwise it would be mahaguni that's in german but also wait can you feel me for a second okay it literally makes me mad when people get all upset about aladino's pronunciations english is aladino's fifth language so you can all learn five languages and then you can get mad at his pronunciations but like fifth language people okay what i can work on though is word flow and uh getting nice sentences no your sentences are amazing i mean i speak one and a half languages and in my half language it's pretty terrible so yeah um this should be pretty simple stuff it's okume plywood it is the not a real mahogany it's mahogany yeah don't even wear it not a subspecies um but still it is very good for boat building and it is the lightest of the mahogany mahogany subspecies there is sapele meranti well then there is a very luxurious kaya which is less used in plywood it's more just a solid wood i really like working with this stuff this is glued to lloyd's specifications which is for boat building so there is no voids in the face there is no voids inside it is glued with boiled and waterproof glue those are all pretty critical things for both building plywood and i just like how uniform the grain is uh so it makes it nice to work with instead the douglas fir that i've been seeing it seems like every layer works against the other and they're very different because you have those very pronounced rings and it warps more and this is more like a uniform thing i really like this and it does come at a cost it does come at a cost but it still is one of the cheaper ones um for boat building for boat building yeah of course um a sheet at the moment is about 140 bucks for one sheet for one shoe so it's pricey half an inch on the other side if you think that the home depot crappy plywood costs 70 a sheet um yeah i find that expensive for the quality difference yeah quality difference yeah and another thing i might say about oklahoma it's it's not the prettiest to the look many they work with dyes so they color it a little bit if you want to use it for finish but i mostly use it where either it's going to be painted fiberglassed over or is not visible [Music] making the jig had not gone as smoothly as planned we made mistakes we realized how bad our math skills are and the end result was a sort of improvised jig which although functional wasn't quite as effortless as we had wanted but in the end everything worked out and now we're one minute step closer towards a sailboat fit for the sea [Music] [Laughter] [Music] before we sign off from this video i do want to say a really really really big thank you to a few people first of all on the list is charlene so we publish real-time patreon updates every tuesday on patreon usually in video format while this whole refit is going on although once we get back in the water it'll go back to a written format anyway so in one of those patron updates i was filming aladino in the interior and we have this 24 to 70 millimeter lens which isn't super duper wide and so like i couldn't get the whole interior shot that i wanted so i just made a quick comment on there i was like well i'm sorry you can't see the whole interior right now but i i can't back up anymore and our lens isn't wide enough charlene instantly jumped on that she's like oh if you need a wider lens let me get that for you uh so she bought us a wider lens it's what we're using to film right now and it's made a huge difference because we can get this really beautiful wide-angle view of the interior now which i think really makes a difference and gives you a much better sense of space so thank you charlene um so wow i mean that what unusual circumstances we do fully realize how lucky we are and how rare this is to have donors like this i think it goes to show how powerful it is to share your story with other people we feel really fortunate to be able to do that so thank you guys alright so i think that's it for this week thank you so much for watching we appreciate everyone who watches these videos and are so glad we got to share our story with you if you enjoyed what we shared today then please give us a thumbs up leave a comment subscribe to the channel hit the notification bell if you disliked the video then press the thumbs down button twice and an extra big thanks to our patrons for really going the extra mile to make sure that these episodes keep happening and an extra extra big thanks to these folks whose names are now magically appearing on screen from ensuring the continuation of magic carpet videos every friday we'll see you all next time look at our wide lens it gets wider as i walk back really cool

Channel: Sailing Magic Carpet

Views: 59,111

Rating: 4.9675536 out of 5

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Id: qAkyBeVQHzo

Length: 25min 31sec (1531 seconds)

Published: Fri Aug 13 2021