Uncle John's Choupique Road - Sulphur, LA 70665

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Carmel Hoover
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1 Uncl John's 5229 Choupiqu Road - Sulphur, LA Thank you for purchasing my plans. Should you hav any qustions whil building your Jon-boat don't hsitat to mail, uncljohn@uncljohns.com or call, I'm happy to hlp. Th singl most difficult stp in building your boat may wll b dciding th lngth and width. You may incras th width of your boat simply by incrasing th width of th bow plat, transom and sat units. Th width masurmnts shown ar for a boat with a bottom width of 30". If you want a boat with a 36" bottom simply add 6" to th masurmnts shown. Th width of ach sparat pic should b incrasd qually. Lngthning th sidboards incrass th lngth of th boat. Bcaus th matrials rquird will vary with th siz you build, a normal matrials list has not bn includd. Th boat may b built with a 30" bottom, from 10' to 12' long using two shts of 1/4" plywood. And, up to 15' 8" with four shts. Th amount of fibrglass cloth and paint as will th lngth of th matrial usd for th rub rails will b dtrmind by th lngth of th boat. Th numbr of scrws ndd will b dtrmind by th numbr of clamps you hav. W do not rcommnd building lss than 10 ft. Bcaus of th variabls w ar also unabl stimat th wight of th finishd boat or to giv any ratings as to capacity, displacmnt or motor siz. Sht #1 matrials Sht #2. USCG rgulations Sht #3 rip plywood to propr sizs Sht #4 scarf join sidboards and bottom Sht #5 cutting th bow plat Sht #6 cutting th transom Sht #7 cutting th sat units Sht #8 lay out and cut th sidboards Sht #9 attaching th sidboards, sats and rubrails Sht #10 fibrglassing th sat units Sht #11 attaching th bottom and finishing NOTICE: Car should b xrcisd in th compltion of th stps involvd in constructing this boat to assur a sturdy craft. Th safty of this boat is dtrmind by th buildr and usr. Uncl John's assums no liability for th finishd projct. As with any watr craft, lif-jackts should b worn and caution xrcisd in rgard to wathr and watr conditions.

2 Sht #1 matrials Plywood: Th basic diffrnc btwn most marin plywood and xtrior plywood is that marin plywood dos not contain voids. Both contain ssntially th sam glus. Taping th sams and dgs with fibrglass will ffctivly sal th dgs. Extrior plywood is considrably mor conomical and is a standard stock itm at lumbryards. W hav had good rsults with both A/C fir and B/C pin. Lauan mahogany is usd by many small boat buildrs. Lauan is prtty, asy to work with and vry conomical. Glu and fastnrs: Thr ar numrous watrproof and watr rsistant glus on th markt. For th most part, glus, nails and scrws hold th structur togthr prior to taping th sams with fibrglass. Onc th sams ar tapd, th fibrglass will provid a strong watrproof joint. For this rason, th typ of glu is of lss importanc than taping both sids of all sams and joints with fibrglass. Fibrglass: All sams and joints should b fibrglassd insid and out for strngth and to sal th dgs. Epoxy rsin is th bst, polystr is th most conomical and th asist to obtain. Polystr rsin can b found lumbryards and auto parts stors. A good sourc for poxy may b found from Paint: Epoxy must b protctd from sunlight or it will dgrad. Painting is asy and durabl. 100% acrylic xtrior latx (watr basd) hous paint works wll. It is conomical, fast drying and vry durabl. Watr basd paints gnrally stick wll to poxy whr som oil basd paints hav adhsion problms and oftn rquir mor prparation. If you wish to stain your boat and us a clar finish you should us a watr or alcohol and not oil basd stain. Allow th stain to dry thoroughly bfor applying th rsin. A good marin varnish will protct th poxy and show th bauty of th wood.

3 Sht #2 USCG rgulations Th following information will hlp you dtrmin th siz boat that bst mts your nds. Th following was xtractd from th USCG wbsit, "Th maximum horspowr capacity markd on a boat must not xcd th horspowr capacity dtrmind by th computation mthod discussd in paragraph (a) of this sction. (a) Th maximum horspowr capacity must b computd as follows: (1) Comput a factor by multiplying th boat lngth in ft by th maximum transom width in ft xcluding handls and othr similar fittings, attachmnts, and xtnsions. If th boat dos not hav a full transom, th transom width is th broadst bam in th aftr most quartr lngth of th boat. (2) Locat horspowr capacity corrsponding to th factor in Tabl (3) For a boat with a factor ovr 52.5, if th horspowr capacity calculatd in Tabl is not an xact multipl of 5, it may b raisd to th nxt xact multipl of 5. (4) For flat bottom hard chin boats with a factor of 52 or lss, th horspowr capacity must b rducd by on horspowr capacity incrmnt in Tabl Tabl Outboard Boat Horspowr Capacity [Comput: Factor = Boat Lngth X Transom Width] If factor (narst intgr) is Horspowr Capacity is [Not: For flat bottom hard chin boats, with factor of 52 or lss, rduc on capacity limit (.g. 5 to 3)] Th Coast Guard formula to comput th saf load of a hom built boat is as follows. Dtrmin th amount of wight it taks to "sink" your boat. Put th boat in th watr and fill it with watr counting th numbr of gallons it taks for th gunwals to b vn with th watr. Watr wighs ight pounds pr gallon. Multiply th numbr of gallons by ight and you will know th total amount of wight it taks to "sink" your boat. Th boat will not actually sink bcaus wood is buoyant. Th Coast Guard thn rcommnds multiplying th total wight by a factor of.3 to dtrmin th "maximum saf load". th full USCG rgulations may b viwd at

4 Sht #3 rip plywood to propr sizs 10' to 11' 7" in lngth with up to a 33" bottom. Two shts 4' x 8' x ¼" A C B D (bottom) (bottom) 48" E F wast A (sidboard) E B (sidboard) F C (bottom) D (bottom) 11' 6" to 15' 6" in lngth with up to a 48" bottom. wast us for dcking, a third sat and gussts wast us for dcking, a third sat and gussts Four shts 4' x 8' x ¼" rip to width of bottom dsird plus on inch A E rip to width of bottom dsird plus on inch B F C D wast us for dcking, a third sat and gussts wast us for dcking, a third sat and gussts E (bottom) F (bottom) A B C D

Sht #4 scarf joining th sidboards and bottom Scarfing plywood is surprisingly asy. Th formula for scarfing is 8 to 1, using this formula will rsult in a joint as strong as th rst of th matrial.

By doing thm all at th sam tim, thy will all hav th sam angl. Stack th pics offstting ach from th on blow by 2". A pic of scrap placd on top will aid in achiving a smooth bvl.

5 Sht #4 scarf joining th sidboards and bottom Scarfing plywood is surprisingly asy. Th formula for scarfing is 8 to 1, using this formula will rsult in a joint as strong as th rst of th matrial. If th matrial is 1" thick, th scarf would b 8" long. Th lngth of th scarf for ¼" plywood is 2". Scarf all of th pics of th sam width at th sam tim. By doing thm all at th sam tim, thy will all hav th sam angl. Stack th pics offstting ach from th on blow by 2". A pic of scrap placd on top will aid in achiving a smooth bvl. Tacking th pics to a flat work surfac will stabiliz th pics whil you ar scarfing. (#1) Plac th first pic on th work surfac and tack it down at last two and on half inchs from th nd. (#2) Plac th scond pic on top offstting by 2" and tack it down. Th tacks should b placd so as not to b in th ara that is to b workd. (#3) Continu to stack th pics as shown. (#4) Using an lctric plan, blt sandr, random orbit sandr or vn a pic of coars sandpapr wrappd around a pic of two by four "grind" th pics until a smooth surfac is achivd. (#1) 2 1/2" 2" Work surfac #2 2 1/2" 2" 2" Work surfac gluing 3" finish nail or scrw wax papr #3 2 1/2" 2" 2" 2" wax papr (hols in plywood ar filld aftr jig is rmovd.) Work surfac #4 Work surfac

6 Sht #5 cutting th bow plat Bow Plat 1. Rip a pic of 3/4" plywood 6 3/4" x 36" 2. St blad on tabl saw at 20 dgrs and rip dg as shown. tabl 6 3/4" sid "A" sid "B" f n c st blad at 20 dgrs 3. St blad on tabl saw at 45 dgrs and rip angl on opposit sid. tabl 6 3/4" sid "A" sid "B" f n c st blad at 45 dgrs 4. Plac sid "A" down and cut th compound angls on th nds of th bow plat. 10 o 34" 17" 17" 6 3/4" sid "B" 15" 15" 30" 5. Whn th bow plat is placd with th "A" sid up, th bvld dgs should fac you. sid "A"

7 Sht #6 cutting th transom Transom 1. St Blad on tabl saw at 15 dgrs and rip a pic of 3/4" plywood 15" wid. sid "A" 15" sid "B" f n c tabl st blad at 15 dgrs 2. Turn pic and rip angl on opposit sid. 15" sid "A" f n c tabl sid "B" st blad at 15 dgrs 3. Plac sid "A" down and cut th compound angls on th nds of th transom. 38 1/2" 19 1/4" 19 1/4" 10 o 4. Whn th transom. is placd with th "A" sid up, th bvld dgs should fac you. sid "A" 15" sid "B" 15" 15" 30"

8 Sht #7 cutting th sat units sat 1 sat sat 1 39" 19 1/2" 19 1/2" attach 3/4" x 3/4" strips to sat parts as shown. Th nds of th strips on th sat tops (part 1 & 3) will nd to b bvld to fit whr it mts th sidboard. 39 1/2" 19 3/4" 19 3/4" 1 Sat 1 part 1 12" 20" 20" 40" Sat 1 part 2 2 8" 15" 15" 30" sat 2 39" 19 1/2" 19 1/2" 19 1/4" 38 1/2" 19 1/4" Sat 2 part " 38" 12" 19" Sat 2 part 4 4 8" 15" 15" 30"

9 Sht #8 lay out and cut th sidboards Th lngth of th sidboards dtrmin th lngth of th boat. Th finishd boat will b 1 to 1 1/2" shortr than th lngth of th sidboards. Carful attntion must b givn whn laying out th sidboards. Layout is not difficult, simply us a framing squar to transfr th layout masurmnts onto on of th sidboards. Stack and cut both sidboards at th sam tim to assur idntical sidboards. If you xcd 12' in lngth you should add a dck in th bow to strngthn th boat. Simply cut 1/4" plywood to fit and glass it in plac. Should you dsir to add a third sat, locat sats 1 and 2 and plac th third sat btwn sat 1 and th bow. Should you dsir to "strtch" your boat to 12', incras th distanc btwn sats. If you incras byond 12', us th masurmnts shown and add a bow dck, third sat or both dpnding upon total lngth. Bcaus th dimnsion of th third sat and bow dck must b mad to fit th lngth w hav not includd dimnsions for th third sat or bow dck. For th most part, boats ar built "to y". It is mor important for th lins of a boat to b "fair" thn for xact masurmnts to b followd. Whn installing th sats you may find that shifting thm a fw inchs will tru th lins. 10'-1" to 15'-8" 1 6 8" bow 6½" 4½" 2¾" 1¼" ¼" 14¾" rub rail sat 1 sid rail 41 ½" sat 2 25½" auxiliary gusst strn " 6" 6" 6" 6" 6" 6" " 4¾" Uncl John's 5229 Choupiqu Road - Sulphur, LA copyright 2000

10 Sht #9 attaching th sidboards, sats and rubrails No. 1 Attach sidboards to bow and transom using both a watrproof glu and 1½" scrws. Th compound angls of th bow and transom will caus th sids to bow outward crating th basic shap of th boat. sidboard bow strn sidboard No. 2 Insrt cntr sat support first. Us a scrap guid across th bottom of th sidboards to position bottom of cntr sat support. as shown (fig. #1) and glu in plac. A pic of rop around th boat can b usd to "pull" th bottom of th sid boards to th sat supports. Aftr sat supports ar in plac attach sat tops. sat 1 sat 2 SIDEBOARD fig. # SEAT SUPPORT 4 SCRAP GUIDE No. 3 Rip ¾" x 1¼" lumbr for rubrails and ¾" x 1" for th sid rails. Attach rubrails and sid rails with ¾" scrws. If you build you boat ovr 12' in lngth add an intr rail as shown in fig. #2 to strngthn th boat. Attaching th rails will stiffn and shap th boat. Bgin at th strn and chck for squarnss as attaching rails. Aftr attaching rails but prior to attaching th bottom, tmporarily attach a stringr (using only scrws) 2" abov th bottom of th sidboards to shap th boat prior to attaching th bottom. Aftr th bottom is attachd th stringrs ar rmovd and th scrw hols filld. fig. #2 rub rail SIDEBOARD sid rail stringr rub rail sid rail intr rail stringr

Sht #10 fibrglassing th sat units fibrglass all joints on th sat units on both sids with 3" wid 6 oz. cloth. 1st.

incras pntration into th wood fibr and holding strngth.

Put cloth in plac and saturat with rsin. Whn th cloth is saturatd it will bcom virtually invisibl.

11 Sht #10 fibrglassing th sat units fibrglass all joints on th sat units on both sids with 3" wid 6 oz. cloth. 1st. Us a tongu dprssor to crat a cov on th insid sams with a mixtur of fibrglass rsin mixd with fillr or fin sawdust. 2nd. Paint rsin on th ara to b glassd. If you us polystr rsin, for th first application, add on tablspoon of acton to ach ounc of rsin, thinning th rsin to incras pntration into th wood fibr and holding strngth. This is not ncssary whn using poxy and is only for th first coat using polystr. 3rd. Put cloth in plac and saturat with rsin. Whn th cloth is saturatd it will bcom virtually invisibl. It is important to saturat th cloth but not to th xtnt to "float" th cloth off th surfac. Th txtur of th wav may b floatd with a scond coat of rsin. Ovrlap cloth by 2" whr ndd. 4th. Aftr th rsin has curd, punctur any bubbls and rglass. Th dgs of th cloth may b fathr on by sanding to blnd th cloth into th wood.

12 Sht #11 attaching th bottom and finishing No. 1 ATTACH BOTTOM. Tack bottom in plac and mark hull shap. Add ¼" all around. Rmov and cut bottom. Attach bottom starting at th bow using watrproof glu, 1" brads into sidboards whr ndd and 1½" scrws into transom and bow plat. Trim bottom flush with sidboards and as th cornr, (fig. #4). Aftr attaching bottom, fibrglass sams on both sids. If you don't hav a "prfct" joint, don't b ovrly concrnd. Th fibrglass rsin will fill small voids. attach bow first rub rail sid rail fig. #4 sat unit sat unit bottom sidboard trim to fit No. 2 ATTACH BOTTOM RUNNERS. Rip lumbr to 3/4"" x 3/4" for bottom runnrs. Attach to th bottom with watrproof glu and 3/4" scrws, bginning at th strn and working toward th bow. runnrs OPTIONS: Clats can b addd to stiffn th bottom. if you build your boat ovr 36" in width and for safr footing. This will also gratly strngthn th boat. An auxiliary gusst is ncssary if a motor is to b usd. If you intnd to us a motor you may want to add a motor pad to thickn and rinforc th transom. An aluminum plat will prvnt th motor from damaging th woodn transom. Salvag and rcycling placs ar a good rsourc for 1/8 and 1/4" plat. Aluminum is asily cut with wood working tools. Handls can b addd to bow and transom. gusst handl gusst bow dck sat 1 sat 2 auxiliary gusst handl gusst clats

13 Visit our sit at to s our othr boats Cajun Pirogu 12' to 15' 7" Bam: 31" Displ: 250 to 350 lbs. Kit: cyprss Skiff-10 Skiff ' 7" or 11' 5" Bam: 47" Sail Ara: 26 to 41 Displ: 500 to 700 lbs. Kit: cyprss and plywood

Uncle John's Choupique Road Sulphur, LA Materials needed to build the basic boat 1/4" x 48" x 96" exterior plywood ~ 3 sheets

Uncle John's Choupique Road Sulphur, LA Materials needed to build the basic boat 1/4 x 48 x 96 exterior plywood ~ 3 sheets Uncle John's 5229 Choupique Road Sulphur, LA 70665 Thank you for purchasing our plans. Have a safe and enjoyable experience building and using your craft. Materials needed to build the basic boat 1/4"