Frame E - almost there!

I’ve reached the second-to-last frame of the project: frame E. This one sits close to the bow and resembles frames C and D, only smaller. The main difference is at the top, where the plans call for bonding a second pine piece to reinforce the beam — this area will eventually take the forestay, so it needs to be stronger than the others.

Frame E - view from the stern

Cutting the pine pieces went smoothly. For the curved components — the two bottom sides and the top beam — I followed the same method I described in my previous post: leave a generous margin when cutting on the bandsaw, then slowly work toward the final line with the rasp, then the file, and finally sandpaper. It’s a patient, almost meditative process now, and I’m getting consistent, clean results. When shaping the two top pieces, I clamped them together and used the rasp on both at once so they would end up with identical curves.

Adjusting the curve on both top beams

The plywood pieces received the same treatment. I cut each one slightly oversize with the jigsaw, dry-fitted it in place, and then removed the excess material with the rasp and the file until it matched the pine frame perfectly. For the top, the plywood spans from one beam to the other so it fills the gap between the two pine layers.

Plywood between the top beams

Removing excess plywood

Once everything fit nicely, I moved on to the usual glue-up: sanding and cleaning all contact surfaces, applying unthickened epoxy, spreading thickened epoxy on one side of each joint, and tightening the screws until I got a gentle squeeze of glue. I then used the squeeze-out to form clean fillets between the plywood and the pine, making the joints both stronger and tidier.

Prepared to glue the first side

Glueing the second beam

After the epoxy cured, I removed the drips with the multitool, then filed and sanded any remaining rough spots. With all the experience accumulated from the earlier frames, this one came together much faster, and I’m happy with the end result.

Frame E - view from the bow

I can clearly see light at the end of the tunnel now. Only one more frame remains — frame D’ — and then I’ll be stepping into a new and refreshing phase of the project.