stitch and glue Archives - Small Boats Magazine

The Education of a Serial Boatbuilder

A little learning is a dangerous thing

That’s according to a poem Alexander Pope wrote more than 300 years before Dennis Ward of Riviera Beach, Florida, figured it out for himself. Reading a book on stitch-and-glue boatbuilding inspired him to design and build a boat in 2004 even though he had no experience with either skill.

Fired at first sight with what the Muse imparts,
In fearless youth we tempt the heights of Arts

Dennis’s muse was Sam Devlin and his temptation was the boatbuilding method detailed in Sam’s book, Devlin’s Boat Building. After reading the book, Dennis went straight to work to create a boat of his own: “I sketched a dinghy on paper, then glued some pieces of wood together with epoxy, and was amazed I had made a boat that didn’t sink.” Cutting out pieces of plywood, drilling a bunch of holes, and wiring and gluing the pieces together just happens to be the easy part, but the goal is more than just keeping the water out. Dennis quickly discovered that the dinghy was unsafe on the water. Pope expressed that awakening of a novice to what has yet to be learned:

But, more advanced, behold with strange surprise
New distant scenes of endless science rise!

The subtitle of Devlin’s Boat Building is “How to build any boat the stitch-and-glue way”. Sam likely intended “any boat” to encompass the sizes and types the system works for—he has designed and built boats ranging from a 6′3″ dinghy to a 45′ motor cruiser—but “any boat” could also be taken to mean good boats as well as bad boats. Sam’s boats, the result of a wealth of education and experience in boat design and construction, belong in the former category. Dennis admitted that his boat had fallen into the latter: “That dinghy has since become yard art.” The lesson he learned was “Let the professionals design the boat!”

Photographs by and courtesy of Dennis Ward

In October of 2021, Dennis retired after a 35-year career as a Palm Beach County ocean lifeguard, rower, rescue-boat driver at Jupiter Inlet, Boynton Inlet, and Boca Raton Inlet. A couple weeks later, he got all six of his boats in the water for some photos. At the water’s edge, from left: Dennis’s self-designed dinghy, kid’s rowboat from a thrift store, Passagemaker Dinghy, Gloucester Gull, and Ben Garvey. The Gloucester Rocker is safely away from the water. His Chester Yawl isn’t shown.

Despite the disappointing results of his first efforts, Dennis thoroughly enjoyed the time he spent building the dinghy. For his second boat, he skipped the designing and bought a kit for Chesapeake Light Craft’s 11′ 7″ take-apart Passagemaker Dinghy. He finished it in 2007 and, although it had all the characteristics that would put it in the “good boat” category, the Passagemaker was only afloat a few times before Dennis was back in his back yard under a 10′ by 20′ canopy, “making more sawdust.” His series continued with a Gloucester Gull and a partially built child’s rowboat he bought in a thrift store for $30. The Gull was afloat only a few times, and the little rowboat has yet to be launched and is waiting for an interested kid he can give it to.

The mild weather in Florida made it practical for Dennis to build the garvey outdoors under a canopy.

One of Dennis’s friends bought plans for Doug Hylan’s Ben Garvey, decided the project was more than he could manage, and gave the plans to Dennis, who started building it in 2011. After he had finished the hull and flipped it right-side up to begin work on the accommodations, he decided to do away with the center thwart. “That way I wouldn’t be stepping over it, and there’d be 8′ of space on the bottom for horizontal activities, like napping.”

Having decided to omit the center thwart to open up the center, Dennis devised a structure that provided a walk-through passage between partial side benches and framing across the bottom.

 

A cockpit sole over the added interior framing provides a smooth surface for napping and enclosed spaces for flotation.

Concerned about losing the strength the thwart would have provided to the hull, he replaced it with two enclosed storage-compartment seats on either side. “I also intended to add several more frames on the bottom to add more strength to the chines and sides. The extra frames would be a tripping hazard and make napping uncomfortable; adding a cockpit sole on top of the frames seemed to be the ideal solution. I ended up with a double-hulled boat with flotation in between.”

The teak rails were painted over in a beige/orange color. The boat's interior is light blue and the outer hull is electric blue.

The gunwales are teak and were initially varnished but Dennis decided “it’s like lipstick on a pig. This is basically a workboat, not a fancy piece of furniture.” He also embedded tie-dyed fabric on a pane forward and a hatch aft “because I wanted to learn how to do that. What I didn’t know at the time is that I coulda bought clear epoxy, instead of regular yellowish epoxy. So the tie-dyed bright whites turned yellow.”

Dennis finished building the garvey in 2012 but then left it on sawhorses under a canopy for several years until he could afford a trailer. A few more years drifted by as he saved enough for a 25-hp outboard for it.

Dennis worried that his weight in the stern along with that of the motor and fuel tank would cause the bow to rise too high, but It sat in the water perfectly.

While the garvey waited, Dennis’s mother gave him the plans for the Gloucester Rocker as a Christmas present. That was in 2017, and all through the following year he worked on it without telling her. The hull and rockers were straightforward work but the seat and grab bar—fashioned from walnut and holly that he had harvested on his mother’s lot—were not. The curved and beveled joints were not easy to get right and by the time he got perfect fits, the two pieces had taken more time than the rest of the boat. The next Christmas he surprised his mother with the rocker; she was delighted with it and she uses it to hold her dog’s toys.

The square bow of the Garvey just barely lifts out of the water while Dennis mans the tiller. Rob Rogerson

On the boat’s first sea trial, Dennis was “somewhat surprised how powerful the 25hp motor was. The garvey is a heavy boat but it got up on plane right away and I wasn’t comfortable going any faster than half throttle. An hour later, the garvey was back under the canopy.”

The garvey was finally ready to launch in 2020, but it wasn’t launched until this year for what Dennis says are “various lame reasons. Mostly, I’d rather build boats than go boating.”

The 15-foot Chester Yawl is supported by sawhorses and lines from the basement roof. The boat's hull is completed and Dennis's mom smiles while examining it... possibly she, too, is impressed that the boat fit in the basement.

Dennis’s 15′ Chester Yawl kit boat is being built with the help of his 86-year-old mother. She offered her basement for the project.

And he has been building boats. A Chester Yawl is in the works in his mother’s basement in North Carolina. Earlier this year, Dennis built the molds and a ladder frame for the L. Francis Herreshoff pram featured in John Gardner’s Building Classic Small Craft. The hull of the 10-footer is usually built in lapstrake cedar on steam-bent white-oak frames, but Dennis had been given a generous assortment of sapele strips and was eager to turn them into a boat.

In fearless youth we tempt the heights of Arts

Strip-building would be uncharted waters for him and, more cautious now after the experience of his first dinghy, he floated the idea of strip-planking the pram on the WoodenBoat Forum. He was dissuaded from making an attempt that could waste time, money, and valuable wood.

New distant scenes of endless science rise!

Rather than forge ahead, he bought Nick Schade’s book, Building Strip-Planked Boats. “I’ll read up some more before I decide what to do.”

Dennis is happier building boats than using them: “The prominent pleasure of wooden boats is in all the different things I learn in the building process.”

 

Do you have a boat with an interesting story? Please email us. We’d like to hear about it and share it with other Small Boats Magazine readers.

Campion’s Apple 16

It all started during the summer of 2015 when I decided that it was time to part ways with MAGIC, my 1962 Alberg 35′ glass sloop. I had spent four years and countless hours restoring MAGIC to her former glory, but two years after re-launching I needed a change. While she was not a big boat by today’s standards, the amount of time and money spent just keeping the boat in the water and in good condition was exhausting. The fact that I lived in central New Hampshire and kept the boat 150 miles away in southeastern Massachusetts only made things worse.

I found myself spending more and more time on a beat-up old O’Day Daysailer that had been following me around since college. My family and I romped around the local lakes and estuaries, sailing hard and often. The only money I spent on her was gas for the car and beer for the cooler. At some point that summer, I realized that I was having as much fun on the O’Day as I was on MAGIC, but with none of the stress. Sure, MAGIC was a comfortable boat that could take somebody sailing for weeks at a time, but I was mostly going out for day sails with an occasional overnighter. I could be doing the same thing on a much smaller boat.

At about the same time, I heard about the Small Reach Regatta, organized by the Downeast Chapter of the Traditional Small Craft Association in Maine. It’s not a race, but a gathering of small, traditional sailing and rowing craft. I have always been drawn to the look of classic boats and when I saw the boat lineup on the Small Reach Regatta website, I knew I had to check it out.

I showed up on the first morning of the event and was able to sail on Mike Duncan’s FRISKY LADY (a Chamberlin 15′ 6″ gaff sloop) and on Geoff Kerr’s NED LUDD, an Oughtred 19′ 6″ Caledonia yawl. I fell in love with the Caledonia but it was a bigger boat than I needed. However, the seed had been planted, and I spent the rest of the summer researching the perfect small boat in the range of 15′ to 18′.

The boat had to be pretty and, while I prefer the look of lapstrake, there is a lot of additional setup and framing required that takes a fair amount of time, so I was looking for a stitch-and-glue design that didn’t require a strongback and associated framing. I also like the classic look of a balanced lug-rigged yawl; and with unstayed spars, balanced lug rigs are really easy to set up for launching. The mizzen makes for easy handling. In spite of the appeal of classic boats, I wanted a fast boat, and a planing hull makes this possible.

The Apple 16, a five-strake stitch-and-glue balanced lug yawl designed by Thomas Dunderdale of Campion Sail and Design, came closest to being everything I wanted. The classic lines and balanced lug yawl were just what I was looking for and the somewhat flat aft section of the hull allows the boat to get up on a plane. I’m a sucker for a plumb bow, so as soon as I saw pictures of the Apple 16, I knew it was for me.

Photographs by Jacob Bowser

The plans detail several interior layouts, and provide the option for decked ends . The author designed his own interior with flotation tanks and a removable center thwart.

 

After several conversations with the designer, I purchased plans and began the build. Thomas was very helpful, answering all of my questions via email or phone.

I didn’t want to wait for a shipment of full-sized printed plans mailed from England; I opted for digital files and took them to a local copy shop and had them enlarged for about $30. I was really happy with the amount of thought and detail that went into the plans; they came with a general construction narrative, a detailed 30-page keyed construction index and at least a dozen schematics for the boat, parts, and interior layout options. For a first-time boat builder, everything provided should be easy to follow.

The included materials list calls for four sheets of 6mm marine plywood scarfed lengthwise for the hull, two sheets of 6mm for bulkheads and interior framing, and one sheet of 9mm for the rudder and additional components.

With a solo skipper aboard, the Apple 16 can, in spite of its traditional appearance and rig, get on plane in a moderate breeze.

While Campion does not currently offer files for a CNC mill, someone savvy with a CAD system should be able to digitize the planking measurements and send them off for cutting to save time. I don’t have easy access to a CNC mill, so I opted to plot the strakes on the scarfed panels and cut them out myself. The plans package provides both a table of offsets and a visual diagram for plank measurements that is very intuitive.

Probably the best thing about building a stitch-and-glue boat is how fast you can make visible progress. Once you cut the strakes from the scarfed plywood panels, assembling the hull is a simple matter of drilling out holes for wire or zip ties (I opted for zip ties) and stitching the panels together. In a single, albeit long, afternoon you can go from a pile of flat plywood pieces to a structure that resembles a boat.

The author could comfortably row the Apple 16 at around 3 knots. His sectional oars, with carbon-fiber ferrules, stow neatly out of the way while sailing.

Of course, it’s not all a piece of cake. Until you get the bulkheads tied in, the entire structure is a bit of a wobbly mess. I cut cradles to steady and align it while I tied everything together. This helps immensely when one is working alone.

The job of taping the inside and outside seams, followed by a layer of 6-oz ’glass on the outside of the hull is rather monotonous. If you’re careful, cleanup should be a relatively minor job and once complete, you can move on to fitting out the interior.

The plans provide layouts for several interiors ranging from a spartan setup of three thwarts, with two doing double duty as mast partners, to a more extravagant layout with decks fore and aft. I deviated from the plans and designed my own interior with built-in flotation compartments and a center thwart that’s removable for camp-cruising.

The boat is quite light, and a solo sailor could add some ballast to stiffen the hull against the press of the sails. The designer recommends adding between 110 to 275 lbs if ballast is needed.

The plans call for a long, open daggerboard trunk to accommodate multiple mizzen sail plans (the larger plan changes the center of effort and requires the daggerboard to be located further aft). Since I was only building the version with the smaller sail plan, I shortened the daggerboard trunk after consulting with Campion.

I also increased the thickness of the daggerboard from 25mm to 33mm so I could build a NACA 0012 foil. I’ve had several opportunities to test performance against other similar designs with balanced lugs and I believe that the foil helps with upwind performance.

All told, the build took me about eight months of working 10–15 hours per week, and I couldn’t be happier with the way it turned out. A single rower with 9.5’ oars can propel the boat at 3 knots when rowing at a comfortable pace, and her sailing ability has exceeded my expectations. Trailering with my four-cylinder Rav 4 is easy.

I’ve had the boat out for dozens of times in a variety of wind conditions, and the boat is really amazing to sail. Having no prior experience with balanced lug rigs, I spent a lot of time researching balanced lug sail tuning and after a bit of trial and error, I opted to go with 6:1 downhaul and 4:1 mainsheet tackle. I used Dyneema line for the downhaul and main halyard to maximize luff tensioning ability.

The Norwegian tiller may take a bit of getting used to if you haven’t used one before, but it is the simplest arrangement for getting around a mizzen mast and has a number of advantages over a conventional tiller.

With the rigging configuration sorted out and making sure the downhaul tension is drum tight, I found that the pointing ability was quite good. Combined with the foil daggerboard, which should theoretically increase lift, the Apple 16 is not far off the pointing angles that a similarly sized Bermuda-rigged boat can achieve. When soloing, I regularly get up on a plane on a reach and hit 8.5 to 9 knots in less than 15 knots wind. Over 15 knots and I put in a single reef, and have sailed in conditions up to 23 knots without being terrified.

We have had four adults out for a sail, and while it is manageable, two of the crew need to sit in the well on either side of the daggerboard trunk forward of the thwart. The 250-lb boat is really best suited for one or two, and each additional crew member reduces the boat’s ability to plane. I have yet to be able to get the boat on a plane with more than two crew on board; I suspect that it would have to be pretty windy to do so. With that said, the boat sails well even with four on board.

The boat is as well-mannered as a light boat can be and is reasonably dry in most conditions. Beating close-hauled into chop over 2’, predictably, tends to be the wettest point of sail. The yawl rig contributes to a very balanced helm on all points with just enough weather helm on the Norwegian push-pull tiller to take any of the play out of the system and allow you to make subtle course corrections.

The Campion Apple is a well-thought-out small boat that is lively to sail and will turn heads in any harbor. It’s a good choice for a first-time boatbuilder with woodworking skills who doesn’t want to spend years building a boat that looks and sails great.

Matt Bowser, a software engineer living in Canterbury, New Hampshire, can’t remember a time when he wasn’t obsessed with boats. He grew up sailing the coast of New England from Rhode Island to Maine and is enamored with the simplicity, ease, and low maintenance of small boats. When he isn’t sailing, building, or fiddling with various boat bits, he’s mountain biking in the forests of New Hampshire and Vermont or trying to get his teenage children to hang out with him.

Apple 16 Particulars

[table]

Length/15′ 10″

Waterline length/14′ 4-1/2″

Beam/5′ 3″

Draft, board down/3′ 9″

Sail Area/123 sq ft

Ballast, if used/110 lbs to 275 lbs

[/table]

Plans for the Apple 16 are available from Campion Sail and Design, based in the UK. Prices are in Pounds Sterling: £65 (approx. $79 USD) for PDF, and £120 (approx. $146 USD).

Is there a boat you’d like to know more about? Have you built one that you think other Small Boats Magazine readers would enjoy? Please email us!