Fillet Brazing for Custom Boat Hardware

By using a brazing alloy that would build up in fillets at the intersections, the resulting radiused transitions would have the appearance of custom-cast fittings.  After some experimentation with different alloys, I found that Harris Safety-Silv 45% Silver Brazing alloy, purchased in a coil of 1/16” wire, produced a nice fillet with a golden color that is a good match for brass, though not quite so dark as bronze.

Boxing a Bigger GPS

The larger screen is much easier to read than the screen of a handheld GPS. The box makes the unit self contained and portable.

I’ve been watching with interest the adoption of waterproof electronics by kayak anglers. The GPS units they usually use have 4” to 5” screens, are waterproof, and have waterproof cabling to connect to a waterproof box that contains a small 12-volt motorcycle battery. But these units are mounted to kayaks and aren’t meant to be removed from the boats for use on land or on other boats.

Shop-Made Riveting Hammers

A common ball-peen hammer may have a head that is too heavy; it may buckle the rivet's shaft within the wood pieces it's joining and be tiring for the user. Tom DeVries made riveting hammers to do a tedious job more effetively.

Rivet hammers come with cross-peen or ball-peen heads. This hammer’s head is fashioned from 5/8″ stainless-steel rod, the handle is turned from a 12″ chunk of 1-3/4″ square maple, and the wedge that flares the handle in the head is a sliver of ironwood.


The Skipper and I launch our small sail-and-oar boats from our beach and dock; coming and going we have to negotiate several obstacles. With the boathook we may pole off the beach, fend off from our beach groins, or push off the dock. We’ll also paddle to and from the dock and in and out of the wind shadow created by the shoreside trees. We like to carry as little gear as possible when sailing, so we created a combination paddle and boathook, which we call a “padook.”

DIY Bronze Blocks

Homemade blocks met our goals for light weight, affordability, and a classic look. The two blocks at the left share a single axle, creating a double block.

When Kyle and I decided to build our own boat to take on a trip down the Mississippi River, we decided to make, rather than buy, as many of the bits and pieces as possible to save money and make the build and journey on the boat even more meaningful. We needed five blocks for SØLVI’s sailing rig and looked to see what was available on the market. Traditional bronze blocks were beautiful but heavy and expensive. High-tech blocks for dinghy racing, made of stainless steel and fiber-reinforced plastic, were light and smooth-running, but expensive and not in keeping with the classic look we wanted. Our research led us to L. Francis Herreshoff’s Common Sense of Yacht Design, where we found drawings of blocks that we could adapt to meet our requirements.

5 Handy Tips

A pair of sawhorses make contact with the handles and the leathers, leaving the rest of the oars free for varnishing.

If you find oars unruly subjects for varnishing, you can get them to behave themselves, as Ben Fuller of Cushing, Maine, does by cantilevering them on a pair of sawhorses. With the leathers resting on one, and the handles tucked under the other—weighted if necessary—nothing is in contact with the areas you’ll varnish. Spring clamps either side of the leathers keep the looms from rolling while you’re varnishing one side and allow you to turn the oar over to brush the other.

Insignia Sailcloth

The authors restore old Sunfish, and Kent is a pilot, so a combination insignia is in the works.

Adhesive-backed sailcloth is commonly used for numbers and class insignia on sails. It comes in several colors, and we used Challenge brand, purchased from Sailrite. The lightweight 3.3-oz polyester fabric ensures that the insignia does not interfere with the shape and pliability of the sail. There is a heavier fabric available from Contender that has additional UV treatment and weighs about a half ounce more than regular insignia sailcloth; it comes only in white and is well suited for repairing sails. The peel-off paper backing on Challenge cloth has a grid to aid in tracing out insignias and numbers.

Transom Extensions

The tops of the extensions, squared off inside of the diagonal side panels, serve as steps for climbing aboard over the stern. The bright finished squares of decking are hatch covers.

Many small skiffs would benefit from an extended waterline and increased planing surface. My own 14′ 9″ (4.5m) outboard skiff has deep V-hull shape that makes the ride more comfortable at high speeds in sharp chop, but the hull still weaves from side to side, drags a big wake at in low speeds, and requires a lot of power to get on plane. My boat also has a tendency to hobby-horse at high speeds; while I can stop this by trimming the motor to force the bow down, the remedy reduces top speed and fuel economy.

Trailer Tires

This trailer tire looks brand new—it still has all of the little rubber "hairs" left by the the mold that created it—but the codes molded into the sidewall indicate it is 16 years old. It needs to be replaced.

Imprinted on every tire is a lot of useful information on its size, type, load range, pressure, and date of manufacture. All trailer tires are marked with ST—Special Trailer— and they are not at all like vehicle tires. Trailer tires have strengthened sidewalls that keep the trailer from swaying in turns and allow them to carry the often very heavy combined weight of trailer and its load.

Eton Oar Stands

My reproduction of the stands used by the Eton Boathouse oar maker turned out to be remarkable quick and effective once I gleaned all of the important details from the newsreel.

One shot offered a glimpse of what appears to be the leg of a second stand. I guessed that was supporting the oar handle. The oar blade was cantilevered beyond the support, but it stayed put even with Len planing as vigorously, so something had to be holding the loom down. In another shot, Len did his “nervous tic” twice and both times the loom of the oar come to an abrupt stop in the same place, confirming that there was something fixed over the loom. Len had to give a noticeable tug to get the throat back on the stand, so putting a slight bend in the oar was what held it in position. Brilliant.

« Previous PageNext Page »