The Plan - "Chinook" by Ken Hankinson

My intention is to provide a log to document the building of a welded aluminum boat. The boat is being built by my brother and me at my shop in Juneau, Alaska.  I hope that everyone who is curious about this project will check in from time to time to see how we are progressing.  Thanks for your comments and any support that you might provide. 

 

 

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Tuesday, October 13, 2009

Trailer

We are still trying to adjust the engine, but we have been running at about 4200-4300 RPM and getting about 31 MPH.  It gets about 3.5 miles per gallon and tops out at around 5200 RPM.  The dealer says it should top out at  5800 RPM so we are going to try a new prop.  We originally had an 18 pitch prop and will try 16.  So far it has worked wonderfully, even though I have several projects for this winter like a fish well in the transom, and I should probably put a door on the cabin.

Here are some pictures of the trailer we built for the boat.  We tried to bend the rails at first, but even with a 1.5 Ton chain hoist we couldn't bring it together.  After a couple tries we had to cut the top and bottom and weld it back together. 

Trailer
Trailer
Trailer
Trailer

When we purchased the aluminum we got a piece of 3X3 tubing for the tongue.  We ended up welding a piece of channel to beef it up a bit.  It's pretty bullet proof now. 

Trailer
Trailer
Trailer
Trailer

Trailer
Trailer
Trailer
Trailer

I also included some pictures of the engine mount with the kicker and a few other things we finished up.

Engine
Engine
Mast
Mast

Console
Console

Monday, June 22, 2009

Splashdown

We worked frantically for a couple weeks just before Memorial Day and finally got the boat ready for the water.  On Friday evening after working all day to finish we wheeled the boat down to the harbor at about 8pm and dumped it in the water.  If you can believe it for the maiden voyage we loaded it up with 4 guys and headed out for a weekend of fishing at my brother's cabin at Funter Bay.  We had a great time and other than a few little details that aren't finished it worked great. 

In the Water
In the Water
In the Water
In the Water

In the Water
In the Water
In the Water
In the Water

In the Water
In the Water
 

For our next project we need to turn this stuff into a trailer.

Trailer Parts
Trailer Parts
Trailer Parts
Trailer Parts

I hope you enjoy the pictures, and I look forward to posting about some of the little details that we have been finishing up.

Sunday, May 17, 2009

Move to Trailer

I got back from vacation several weeks ago, and we have been steadily working of finishing up all the details in order to get the boat in the water.  I finished installing the side windows, and cutting out the back windows.  We are in the process of getting quotes for front and back windows.  Hopefully they will get installed this week.    

Side Window1
Side Window1
 
Side Window2
Side Window2

Back Windows
Back Windows
Deck Fasteners
Deck Fasteners

Saturday morning I added a bowsprit and Sampson's Post to the bow area.

Bow4
Bow4
Bow5
Bow5

This afternoon we wheeled the boat out of the shop and transfered it to a trailer.  We had to borrow a trailer since ours is not put together yet.  We are still waiting on parts from Seattle for that little project.   The boat rolled right onto the trailer with no problems and is ready to go to the glass shop.  My brother has had us working frantically the past couple weeks to get everything done before memorial day.  He has some friends coming into town on Friday and wants to have it in the water by then.  We still have a short list of things that need to be completed first, with the most important being windows and  mounting the engine. 

Transfer1
Transfer1
Transfer2
Transfer2

Transfer3
Transfer3
Transfer4
Transfer4

I hope you enjoy the photos.

 

Sunday, March 22, 2009

Side Windows

We found some sliding Diamond Sea Glaze side windows that are perfect for our boat.  The windows didn't fit the boat they were made for, so we got them for a very good price.  I included a picture of the cabin with the side windows cut out and trim added.  We had to add the trim because the windows were made to fit a boat with sides about 3/4 of an inch thick.  The Trim will also help stiffen  the sides.

Window
Window
Cabin
Cabin

Window Trim
Window Trim

 We have also made a bench seat at the back of the cabin, and I cut out the plates for the back deck.  The deck still needs to be fastened down, but it makes it a lot easier to walk around.

Bench Seat
Bench Seat
Back Deck
Back Deck

I am going on vacation next month.  While I'm gone Bob is supposed to get parts for a trailer and finish as much wiring as possible.  There is still a lot to do, and I hope to have it in the water by summer.  It may still be a bit ruff around the edges, but I think it will happen.

Saturday, February 14, 2009

Console

One of our big projects lately has been to build the console, so we can start running control cables for the engine.  I have a series of pictures that shows the console going together.  It took us much discussion to finally come up with the basic design.  I wanted it to have some curves, and we had to figure out how to get enough room for switches and gages.  The first picture shows the face that we finally came up with.  The second picture shows the process for measuring the top plate.

Console1
Console1
Console2
Console2

The next two pictures shows me transferring the measurements to a flat plate, and using a batten to draw the curve. 

Console3
Console3
Console4
Console4

I then had  to figure out how to clamp the top in place.  I wish I had a picture with all the clamps in place.  They were sticking out all over the place by the time I was happy with it. 

The final picture shows it all welded together.  It needs a good polish job.  We are down to working with whatever is in the scrap pile, so most of it is scratched or tarnished.

Console5
Console5
Console6
Console6

I think it came out pretty good.

Thursday, January 15, 2009

Christmas Projects

I get about a week and a half off at Christmas, so I spent most of the break over at the shop welding.  Bob and I got the roof and cowling tacked in place before he left on vacation.  Over Christmas I got the roof welded all around.   You can see we also cut out the front windows.  We left the cowling a little long on the bottom.  It was a little easier to get in place that way.   It does block the view and is not straight on the bottom, so it will get cut down a little.

Roof
Roof
Roof
Roof

I added some trim and hand holds at  the back of the cabin, and finished all of the trim around the roof.  The  round stock was bent by clamping it in a vice with a piece of rigid pipe over it to keep the bend tight.   

Trim
Trim
Trim - Roof
Trim - Roof

I also cut out some of the deck and welded it in place.  The middle section of the deck will be screwed in place.

Deck
Deck
Deck
Deck

Dave Petersen from Seattle, WA sent me some picture of a boat he designed and built in a friends shop.  He was able to have the plat cut from cad files.  If you don't have the time to cut every piece by hand that's a great way to do it.  His boat has some beautiful lines. Thanks for the pictures.

Dave
Dave
Dave
Dave

Sunday, November 09, 2008

Into The Details

Here is a picture of Dad when he was here in the spring.  He helped us get the fuel tank finished and installed.

Dad
Dad

Now that the main hull and cabin are done we have been working on getting all of the detail work done so that we can put the decks on and finish the top of the cabin.  These picture show what we have done to finish off the rail and get all of the fittings and tubing in place for the fuel tank.  Eventually we will build a fish box into the transom area.

Rail
Rail
Rail6
Rail6

Transom
Transom
Back Deck
Back Deck

Here you can see what we have done in the cabin area.  It is almost ready to start building the steering and controls console and install some seating.

Floor Pan
Floor Pan
Cabin Deck
Cabin Deck

Here are some pictures of conduit and wiring that we have installed under the deck.  We wanted to get some things like the bilge pump and fuel lines installed before we put the deck down.  

Recently one of the marine companies in town decided to move operations to their main office in Sitka, so they sold off everything cheep.  We were able to get some trim tabs and a GPS unit with a depth finder.  We installed the trim tabs and depth finder sending unit now, just in case we needed access under the cabin deck.

Below Deck
Below Deck
 
Trim Tabs
Trim Tabs

I have gotten several emails from several people wanting to build their own project.  I got this picture from Curt Boehm in Troy, NY.  This group of friends is building a 24 1/2 ft design from Ken Hankinson called the Baracuda.  If anyone has updated pictures of a boat they are building I would love to post them.  Especially if you have some special tool or process that you would like to share to make it easier for the rest of us.  Thanks for your comments.  

CB_aluminum boat
CB_aluminum boat