Layout board for my Flicka: s/y RED RASCAL. Photo: Bob Collier © 2013
INTRODUCTION - Several months ago when the editor of “Flicka Friends,” asked me to put together several articles on building a Flicka, I immediately agreed. But on further reflection, since most of you are not boat builders, I felt a certain ennui would set in and you’d hit the delete button. Recently, I was convinced otherwise and that a certain enjoyment as armchair builders would prevail. Also, if not builders, we all are restorers and rejuvenators of our boats. So, if you hang in there and follow me through the creation of a Flicka from a set of plans to the launching, you will see several steps that may cause you to say “I can do that” or “I can add that or modify my boat to include that.” MUSINGS AND RECOLLECTIONS - Now you may wonder what would cause a supposedly sane man to undertake such a prolonged task, especially for 10 ½ years? My interest in this hobby, and it is a joy such as a hobby brings, originated back in the 70’s when my two pre-teen sons asked Dad to enroll them in a sailing course, and wanted Dad to join them. I’ve been sailing since childhood but never had formal instructions. So off we went on a multi-weekend course sailing everything from a 20’ Cal to a 42’ Cal (the Jensen Marine company was just around the corner making Cal boats). Besides sailing we were taught the complete care of the boat and sails. At the completion of the course my son’s enthusiasm bubbled over to “Dad, let’s build our very own sail boat!” Buying into the adage of quality time with your kids, I said “sure!” not realizing what I had bitten off. Talk about “more than one could chew!” I looked everywhere for a boat that came with an 4
instruction manual on how to build it. Just no success until I discovered the Snipe Class organization. It was before Hobie came along it was the largest one-design class in the world. More importantly, it was before nearly all boats were fiberglass and they published a thick manual of step-by-step photographic instruction. I was hooked, even though my son’s enthusiasm flagged and after one week they left dear old Dad for football and basketball practice. I persisted in my spare time and on weekends until after a year we were sailing our plywood-planked wooden Snipe on Mission Bay in San Diego. Since that time I have built two more sailboats, the last one being a Flicka, and accumulated over 50 books on boat building. So, let’s get started! A BACKGROUND ON BOAT BUILDING - Although most of us have purchased a Flicka, which nearly always is a production boat of molded fiberglass, many Flickas were built and designed for materials other than fiberglass. If you wanted to build your own boat the same way as a production boat, you would first have to build a “plug.” This is a full-size replica of the boat finished to perfection. This serves as the “male mold” (hull and deck molded separately) from which a female mold is obtained. This “female mold” is then reinforced with iron or steel braces on the outside of the mold to withstand the pressure of several layers of fiberglass either sprayed in, much like the gunite spraying when making a swimming pool, or hand-laid, the latter usually considered the best method today. Then, when the fiberglass cures and is removed from the mold, you have your hull. The deck and trunk house are molded similarly and then attached to the hull. This is Flicka Friends F
accomplished either by “tabbing” in which tabs or extension pieces of the hull are cemented to the deck, or vice versa. Or at times, the deck can be bolted to the hull. This production technique was first introduced in 1956 by the Coleman Boat Works. Some of the older fiberglass boats, including Flickas, were built at a time when knowledge of the strength of the material was not fully known. So, to be sure a boat was strong enough, builders would spray in many more layers than necessary. However, to this day, including the Flicka, these are some of the strongest boats around without any “sandwich” between layers to turn to mush and are generally known as “bulletproof” boats. Custom-built Flickas have been constructed with everything from concrete (ferro-cement) to a variety of wood methods (laminations, plywood planking, strip-planking, carvel, lap-strake, to name a few) and various fiberglass methods. As one example, I have built a day-sailer by a relatively new fiberglassing method known as “CFlex” construction. This method is often used for one-off boats, such as America’s Cup boats when only one or two boats were built to a particular design and quickly. C-Flex is a fiberglass material that consists of 16 glass rods, ¼ “ thick, which are interwoven with cloth strands. It comes in rolls 100’ long and 12” wide (left side of photo with a roll of C-Flex propped against the wall). This technique involves setting up building forms, much like bulkheads, and then stapling the C-Flex to the forms. Because it is flexible one can easily make compound curves with it. Next, the material is coated with a resin. When this dries you have a very hard and solid boat. The staples are removed and a final coat of fiberglass cloth and resin with glass powder is applied After sanding, this produces a smooth surface ready for painting.
An earlier boat building project Photo: Bob Collier © 2013
What could take months to years to get to this point would only take a few weeks with C-Flex. This combination of resin and powder is mixed to a plaster consistency and troweled or brushed on. This is an excellent way to repair damages and dings in finished fiberglassed boats. When dry it is easy to sand smooth. STRIP-PLANKING - I searched through all the resources I could find and narrowed the choice of my next sailboat down to two possibilities. I wanted to build a cruising boat and one that I could build in my garage, not an easy find! One of the two was the Flicka. While I was mulling over the plusses and minuses of the two boats, my wife and I took a short vacation to Mission Bay in San Diego (only a few hours’ drive from our home). While walking adjacent to the local marina, my wife spotted a boat at a side-tie and said “there’s a cute and sort of pugnacious little boat! Why don’t you build that one?” That did it! I told her that that was a Flicka and one of two boats I was considering. Flicka Friends
Working with C-Flex to build a small day sailor. Photo: Bob Collier © 2013
So, on returning home I ordered a set of plans from Bingham who, it turned out, was Fred Bingham, Bruce’s father. I had several conversations with this congenial designer (he even sent me his book on boat joinery gratis). On receiving the plans, which included full-size frame patterns that obviated lofting, and 18 blueprints of the Flicka design by Bruce Bingham, I went over the plans, spot checking measurements to be sure there were no obvious errors on the blueprints to the frame plans to be sure they agreed (one of our cats helped out). The next step involved connecting the frame patterns to form one large sheet (they were photocopied in 3 parts or sheets). Then I constructed a “lay-out” board. Due to the many times one checks the plans, over the years they slowly wrinkle and become a bit tattered, which would result in distorting the measurements. Boat production companies have large “sail lofts” in which full-size patterns can be transferred to the loft’s floor.
Reviewing the plans for my Flicka: s/y RED RASCAL. Photo: Bob Collier © 2013
For the home or custom builder one builds a “lay-out” board. For the Flicka, I took two 4x8 plywood sheets and connected them with braces to form an 8x8 board. I gave this a coat of white paint and now had a surface I could transfer the full-size frame patterns to this board, thus creating a stable surface for each frame pattern (11 in all)---with each frame a different color to make it easier to check and compare parts of a frame against these line patterns. This provided a stable surface, I can’t overemphasize the importance of the lay-out board. The frame determines the shape of a boat. The frames were made in 3 pieces, placed on the layout board and aligned with its frame pattern. Then they were fastened together with gussets or cleats. This was repeated for the other half of the frame and the two halves fastened together. Without the lay-out board I wouldn’t be able to produce the correct curve of the frame and match one side to the other. We come to a close for now, but I have a puzzle, a conundrum for you to ponder before the next issue: It is a 2 part puzzle (1) traditionally the frame patterns provide the forward half of the frames on the starboard side and the aft half of the frames on the port side, all together only half of the necessary information. How do you obtain all of the frame patterns? and (2) How do you transfer the frame patterns to the layout board without cutting, perforating, or damaging the plans in any way?
Working on the lofting for my Flicka. Photo: Bob Collier © 2013
So, like the evening radio serials of yore, tune in the next issue for the next exciting solution when the Green Hornet...oops, I mean the s/y RED RASCAL solves this dilemma. Look for the new adventures of building a Flicka!!! Flicka Friends F