Repair and Maintenance of a Drascombe Lugger


Replacing the Wooden Floor Boards
(page 2 of 5)

This page begins a step by step guide to the construction of the new floorboards.

The project in summary

Estimating the amount of timber required

This is most easily done by measuring the dismantled old boards. It was decided that the larger (longitudinal boards) would be the same size and thickness as the originals, that is 145 mm wide and 20 mm thick. The narrower longitudinal boards and all the bracing boards were constructed from planks 70 mm wide and 20 mm thick. The original bracing boards were thinner than this (15 mm), but the greater thickness makes a stronger structure. The quantities of Redwood Pine required for Sospiri's boards were as follow. Note that the measurements are rounded up slightly to allow for error).

And for the smaller longitudinal boards and the bracing (cross) boards:

If you are purchasing the wood from your local timber merchant then it is important to specify that the above measurements represent the finished sizes, otherwise the timber will end up, after machining, at a smaller size than specified.

Other materials required for coating and fastening the bracing boards in position were:

The MASTER PLAN of Sospiri's boards showing the exact measurements.

The sketch below is a linked to a series of plans and photographs which give the detailed measurements and positions of each floorboard. Note that apart from Board 8, detailed measurements are only given for the Port set of boards as the corresponding Starboard boards are a mirror image and will have nearly identical dimensions.

Detailed sketch plans of the Lugger floorboards Lugger Floor Board Sketch Plans

The main sketch shows the the two sets of floor boards located either side of the centreplate trunk. When viewing the main sketch it is possible to click on each board to display an enlarged sketch and photographs showing detailed dimensions. Click on 'Close Picture' below the main sketch to return to this page.

(Click on image for larger view)

The old and the raw material for the new boards The Old and the New

The old boards of the starboard set are shown next to the new redwood planks to be used for the replacement boards

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Making the longitudinal boards

To avoid getting timbers from the port and starboard set mixed up it is recommended that the two sets are marked up and cut out separately.

Board number 8

We will begin by describing the construction of one of the curved outer boards (Number 8).

Plan of board 8 Sketch plans of board 8

This sketch shows the dimensions in millimetres of both the starboard and port curved floorboards. Note that the two boards are slightly different in size. The following instructions relate to the Starboard board.

(Click on image for larger view)

Marking out a new board (8) Marking out starboard board 8

The photograph shows the starboard curved outer board (No. 8) being marked up ready for cutting. The new timber has been placed on the work bench and the old board positioned above it. The straight edge of the old timber should be in exact alignment with one edge of the new board. Two G clamps are then used to hold the boards in position to enable a pencil line to be drawn round the curve of the old board.

(Click on image for larger view)

Cutting out a new starboard board (8) Cutting out starboard board 8

After using the old board as a template to mark up the profile on the new board, it is ready for cutting out. This picture shows a jig saw with a fine blade (to avoid splintering of the softwood), being used to cut out the new board.

(Click on image for larger view)

Finishing off starboard board (8) Finishing off starboard board 8

After cutting out the board, all the sharp edges were rounded off using a sanding block with Grade 80 grit. Note also that, unlike the original which had a sharp pointed anterior end (See first photo above), the replacement board has a squared off end. This smoothing off ensures that the Epoxy and varnish coatings will have a better key and there is less risk of splintering.

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