So I have been wanting to build a Tom Blake Wood Kook Box for a couple years. Have done some desighns but never came up with one I liked. So I desided to build a Kaholo 14. Because I am lazy it was easy to just order some plans and patterns and leave all the R&D to some one else. The Kaholo 14 has been around for several years and has a reputation for being a fast stable SUP.Could have ordered a kit but that would have ment I didn't have to do anything but put it together. By useing the patterns I can take a simple project and make it into a major undertakeing. All though it is a 14 foot stand up paddle board . To me it is still a surfboard. Afterall surfing didn't get where it is to day without its roots starting with the Hawaiian big wood surfboards then balsa boards, hallow wood kook boxes and then big foam boards.I am going to do this board in Hawaiian Koa wood and the board is dedicated to the Hawaiian people who started all this surfing in the first place . So this is for all you Hawaiian surfers out there !!!
I guess if I am going to build this I had better get the picture thing together or risk getting keel hauled !![IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures086.jpg[/IMG]
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures087.jpg[/IMG] first I took the paper patterns and glued them to 1/4 inch melamine coated masonite so I would have router templates.
IN order to make the templates I taped one side of the pattern to the masonite then folded it down so I could spay 3 M addhesive to the masonite then folded the pattern back up and smoothed it down on the masonite. I did that for all the parts of the Kaholo. Half templates for the large panels and full templates for the fr[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures089.jpg[/IMG]
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures088.jpg[/IMG]ames.
Nice project. Looks like a boat building operation, thankfully on a smaller scale.
GTDF Ya is more like boat building than surfboard building . The evolution of a surfboard desighn is relatively fast, as you can shape a foam board in a couple hours and glass it and have it in the water in a couple days.So if you don't like the desighn you can just shape another one and on untill you end up with what you want. Mowing foam is a lot easier than buildind with wood. It could take a dozen prototypes and a year of your time to get to where you wanted on a wood desighn.Thats why I am doing the Kaholo 14, cause all the bugs have been worked out allready. But a boat it is not !
Longboards are the original, and very first variety of board used in standup surfing. Ever since the sixth-century the ancient Hawaiians have used 8-to-30-foot (2.4 to 9.1 m) solid wooden boards when practicing their ancient art of he'e nalu. Surfing was brought to the Hawaiian Islands by Polynesians and has since become popular worldwide. The ancient boards were carved and fashioned out of solid wood. In another thread I think it was getorat that said something like : You got to mow a lot of foam to become a good shaper ! That is very true. I mowed a little foam back in the 1970s and desided that all the good shaper positions were taken by guys that had allready put in their time. Well IHad put in a lot of time with wood and desided thats what I wanted.
front and back side panel patterns glued to 1/4 inch masonite [IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures090.jpg[/IMG] next I cut front and back bottom patterns [IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures093.jpg[/IMG]into templates.
half template of one bottom panel being faired out with sanding block
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures094.jpg[/IMG]
Sanding block for fairing out templates. Just a sanding pad with 50 grit paper and a block of wood clamped to it to keep ar square angle on the template
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures096.jpg[/IMG]
To make the frames I glued the patterns to masonite and then cut the templates out with band saw and jig saw, and faired them out with a drum sander. Then I double stick taped these templates to 1/4 inch plywood and rough cut the ply with bandsaw and jig saw. Then I routed the assemblies on the router with a pattern bit. Pried appart the assemblies useing a wide chisel.
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures150.jpg[/IMG]
Wood Ogre,
What you can’t see right now is the flat spot on my forehead from slapping my palm into it. Reason, your clamped jig for squaring up templates. Mike
There are several ways to make the long panels for this hull. Scarf joint, which is the traditional boat builders method. Butt block joint , a strong joint but leaves a hard flat spot on the hull panels. And then there is the puzzle joint which is used on kit boats and is made with a CNC router and is a handsome and very strong joint. Because I am useing 1/8 inch none marine plywood which has very thin outer skins it is not practical to use a scarf joint. Butt block would be strong but ugly. I dont have a CNC router to make puzzle joints so I descided to make my own router template to make finger joints which is stronger than a scarf joint and handsome. This is what I want the joint to look like. I figured my joint size to give me the maximum glue surface area and the lenth is enough so I could use it for 1/8 inch 1/4 inch or even 3/8 inch plywood.
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures172.jpg[/IMG]
The CNC guys say that you can not make a router jig that is as accurate as CNC , which is bull shit !! Wood workers have been told that so many times that they believe it so 99% never even try to make a puzzle joint or finger join.Well I've been around for a while and I have done it so they can't shit me. I used to hand cut dove tails for drawers for many,many years so I know that hand cut joints can be as dead on as machine joints. Makeing a router template is part hand work and part machine work . So I used 1/4 inch masonite and used a drill press, jig saw,and several handtools to make my template. First gotta do the layout and this is where you need to be dead on. Here is the start of my template. It took about 2 and 1/2 hours to make it.
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures147.jpg[/IMG]
I am bumping this thread up because I am shooting clear coats yesterday and today and may not have time to post pictures today. If you wanna learn something you just might find something on this thread if you fallow it through to the end. If not, Well sorry for you ! Besided Ambrose hasn't seen this yet !
cutting out the fingers useing jig saw. Cut lines were scribed with exacto knife and sliding t bevel.
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures148.jpg[/IMG]
After the fingers are cut out the ends are rounded with som 50 grit sand paper
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures149.jpg[/IMG]
Wood, your work is on another level. Great stuff. Fascinating. I have the Bosch jig saw, too. It must be twenty years old. I use it every day. Great tool. With a sharp blade it cuts 2x4’s almost as fast as a Skil Saw. If they would put a little blower to facilitate seeing your line it would be a perfect tool.
a forward panel just cut to finish with template router bit.
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures151.jpg[/IMG]
inlay router bit with large bushing is used to cut sockets.
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures153.jpg[/IMG]
left is the finished socket , right is the scrap
[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures154.jpg[/IMG]
Llilibel, most of the new jig saws have the built in fans now. Also nice LED lights too..
Nothing like doing a long cut with the jig and hyperventilating from continuous blowing of the dust. Been there.
Mr. Ogre, great idea on the finger joints. Nice Job. Is that a Freud or Milwaukee router? Love my Milwaukees with the worm screw adjustment. They fit the hand nicely as well. If I were you, I'd make a copy of that template to have as a back up, just in case. It would be nice to have one made out of ABS or PVC sheet.
More pictures up tomorrow
"More pictures up tomorrow"
Can't wait... Great stuff!