Bottom
panels being stitched together at the centerline
The JAM8 is built using stitch-and-glue construction. Panels are cut from thin plywood using the computer-generated offsets. Holes are drilled along their mating edges every 6 inches or so. Wire is woven through these holes to "stitch" the panels together. Fiberglass mesh and two-part epoxy are used to "glue" the joints and seal the wood. Finally the wire is removed and the boat is varnished or painted.
Bottom
panels being stitched together at the centerline
The side panels are attached in a similar manner, but they have rails epoxied to their upper edges as an attachment point for the deck.
Side panels
with rails attached
Stitching
the side panels (with rails attached) to the bottom panels
Detail
of the wire stitching before removal
The boat begins to take shape now. At this point the fiberglass tape and epoxy is used to finish and seal the inside of the boat. Next, curved deck beams are cut to form the supports for the deck. The beams are made of plywood laminations. Lots of clamps are useful at this point.
Clamping
the deck beam laminations while the epoxy cures
The deck is cut to rough shape, the opening is roughed-in, and the deck is glued (and temporarily screwed) down to the rails.
Waiting
for the epoxy to cure
The extra deck material overhanging the sides is planed away. A little sanding, a few coats of epoxy and a coat or two of varnish, and you're done. All you need now is a paddle. We made ours from only the finest closet rod material available...
Clamping
the paddle while the epoxy cures
All in all, the construction experience is very enjoyable. But the best part is paddling it...
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