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One of my favourite stories from my summertime job in a Vancouver Island sawmill in 1967 was the joke that workers liked to pull on naive newbies to the mill. They would tell the unsuspecting victim that a certain pile of lumber had been cut too short and would then send him in search for the “lumber stretcher” to remedy the problem. The unfortunate victim would go from one area of the mill to another, asking for the device, only to be told that he should try in yet another place, until he had covered most of the mill and someone would relent and let him in on the joke. Fortunately for me, the mill workers thought that a farm boy from the prairies would have too much common sense to be caught by such a prank and they didn’t pick on me!

Boat building does have a similar problem to that posed by the mill workers – how to make short boards into longer ones in order to build boats beyond the length of available lumber. Various methods have evolved in the history of boat construction, including the scarf joint (which we will encounter in a future post). The advent of CNC directed routers, able to cut out patterns with great precision, has enabled one modern version of “lumber stretching” that the Mana “cat kit” incorporates – the jigsaw puzzle joint.

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On the Tiki 21 that I built in the 90’s and on most of the modern designs from James Wharram Designs, plywood panels are joined, end for end, in a butt joint with a piece of plywood epoxied over top of the joint. This method is effective and requires no specialized scarfing equipment or expertise but it does not leave a smooth panel on the interior of the hull. The jigsaw joint used on Mana 24  gets around that limitation – a 100mm strip of fibreglass tape reinforces the joint instead of a piece of plywood.

The puzzle joint ensures that the joined panels line up correctly. I followed the advice from JWD and placed MDF board above and below the joint along with plastic sheeting, weighed things down overnight while epoxy cured, and the results were a nice smooth, 23 foot long panel.

Due to the cost of air freight from the UK to Canada, James Wharram Designs suggested that I source the lengths of solid wood required for building the Mana 24. That sounded like an excellent suggestion and it was, but it did lead to a surprise. I was surprised to learn the market for lumber had changed considerably since I built my Tiki 21 during the 1990’s. Mahogany lumber was not available at any of the lumberyards that I called in the area. Even the clear Douglas Fir specified in the plans and which is grown in Canada was  not available from local lumber yards in Saskatchewan.

After many phone calls and considerable searching on the internet, I found a supplier in Edmonton who could provide me with clear Douglas Fir, mahogany and iroko as stipulated by the designer.

On May 1, my partner and I headed west, and after the 5 1/2 hour drive, pulled up outside the warehouse housing W.G. Chanin Hardwoods. The owner, Gary Chanin, had recently broken his leg and was hobbling around the best he could on crutches and with a cast on his leg. We quickly learned that this is a one man operation, and we had to exercise patience while he attended to customers who were there ahead of us,

This provided me an opportunity to snoop around a bit. What I saw still amazes me. In this dark warehouse space there is a collection of exotic hardwoods from around the world that made anything I could have imagined pale by comparison. The photos, shot on my iPhone in poor lighting, only hint at the treasure that is contained in that building.

Gary finally got to us and showed me a pallet of clear Douglas Fir, still wrapped in plastic, which he had recently received. He invited me to pick out the pieces that I needed while he took car of other customers. The shipment was all one inch rough sawn lumber in varying widths and in lengths up to thirteen feet. It took some time for me to select sufficient boards to meet my requirements and load them on my mid-sized truck. Fortunately I had borrowed my brother’s bed extender and that made it possible to carry the long pieces.

We still needed the mahogany.  This required Gary to expertly shuffle many different piles of lumber around with his forklift until he found the correct pallet that held some lovely pieces of mahogany. Once the two required pieces had been extracted,  he then had to return everything to its allocated space.

This left us with only the iroko – one piece was all that was needed. In my multiple phone calls preceding the trip, Gary had assured me that he could supply me with iroko – something that other suppliers had not even heard of. I am quite confident that somewhere in those stacks of lumber, there are some iroko pieces but Gary admitted to me that he did not know where and suggested that he substitute something similar.

Considering that the day was quickly coming to a close, I conceded with some reluctance. Gary produced a lovely piece of Burmese teak that he assured me would be more than adequate for my needs. Without asking the price, I agreed and I loaded  the board on the top of the other boards. While Gary went to tally the bill, I proceeded to tie everything securely and attach flags. It was only after he presented me with the invoice that I discovered that Burmese teak comes with a premium! That one board, measuring approximately six inches wide and ten feet in length, cost just over $250!

On July 19, after clearing the paperwork through Canada Customs in Calgary, Alberta, I took delivery of Kit #3, a wooden crate containing the CNC cut plywood components plus sails, hardware, lines and fastenings required to build a sailboat. The Mana 24 is the first kit boat to be sold by James Wharram Designs. The prototype  boat, #1, designed by James Wharram and Hanneke Boon, was launched in the summer of 2016 at Cornwall, England.  Kit #2 was shipped a week ahead of mine to another boat builder in Norway.

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On my return to Saskatoon, I unpacked the crate, moved  it into our garage, and reloaded everything back in the crate until the time construction would begin. I was pleased to see the plywood components had been packaged to facilitate the construction process with parts sorted into various steps as well as port and starboard sides.

Summertime is for sailing boats, not for building them, and I still had my WindRider 17. Little did I know that my sailing was not going to amount to much – other events and the weather played a role in that.

No worries. With the kit at hand, it was now time to get prepared for the winter ahead, assembling tools and locating a heated workshop.

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Mermaids play a significant role in the myths and legends of my Highland ancestors, assisting them in their journey from Ireland to first the islands and then the mainland of Scotland. I am enlisting their assistance once again as I  embark on my latest project, the construction of a 23 1/2 foot catamaran sailboat. I drew this design to grace the bow of each hull when the boat is completed.

The catamaran is the latest one to be offered by venerated designers, James Wharram and Hanneke Boone. The prototype Mana 24 was launched last year, sixty years after James set out on a boat of the same length to be the first to sail across the Atlantic Ocean on a catamaran. His inspiration for that boat and those for which he subsequently became famous was the sea-going double canoe sailing craft of the Polynesians.

This will be my second Wharram designed catamaran. In the 90’s I built a Tiki 21 and sailed it on Brightsand Lake for three summers before loading it in a 40 foot container and shipping it to Ghana. Here is a shot of it sailing onto the Ghanaian shore in 2002.

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Stay tuned for photos and updates during the construction phase. May the Mermaids of the Prairies ensure us fair winds and safe passage.

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12×16 Acrylic on stretched canvas

For over forty years, sailing has been a passion of mine. In that time I have owned five sailboats of various types and sizes. My lone sailing lesson consisted of an afternoon on Jackfish Lake with my next brother who had learned how to sail while in the Coast Guard. He helped me to set up my first sailboat, a home-built fifteen foot wooden craft that I purchased for $500 and we sailed for a couple hours. After that I was at my own devices, relying on sailing magazines and a how-to-sail book that I had come across in a bookstore. This was long before the advent of the internet and YouTube – it was trial and error hands-on experience.

Somewhere along the way in my reading, I encountered a man who had profoundly changed conventional sailing in Europe with his designs for two hulled sailboats inspired by and modelled after traditional Polynesian sailing craft. In 1956 James Wharram and his two female crew members became the first to sail across the Atlantic on a 23 1/2 foot catamaran that he had designed and built. I became enthralled by his designs and his philosophical approach to sailing with an emphasis on stability and low cost construction. In 1999, I completed the construction of a 21 foot catamaran, designed by James Wharram, using a set of plans drawn by his partner, Hanneke Boon. The boat was a Tiki 21, given the number 97 since mine was the 97th set of plans sold by James Wharram Design for that model.  The reference photo for the painting above was one of the few photos taken of that boat, sailing on Brightsand Lake.