Wooden Boat Restoration Repair - WEST SYSTEM Epoxy

5.1.1 Cleaning out the seams
Getting a good clean bonding surface on each plank edge is the first step. You can use a
circular saw, a router, a chisel and hammer, or a sharpened scraper to clean all the old
caulking material out of the joint and expose clean fresh wood for bonding on the
facing edge of each plank. One tool may work better than another in a given situation,
but a circular saw is usually the most effective way to mill out the seam accurately.
1. Dry the hull thoroughly before beginning. This allows the seams to open to their
widest and stabilizes the size and shape of all the pieces.
2. Tack a batten to the hull to act as a guide for the saw. The batten should be parallel to
the seam so the blade will follow the center of each seam exactly.
3. Select a blade or reset the blade’s teeth wide enough to shave the edges of both planks
facing the seam. Use a pair of pliers to bend the teeth for more set. The seam width may
vary, but the cut should be at least 3 16" If the seams have opened very wide after drying,
two passes with the saw may be necessary to shave both planks.
4. Set the depth of the cut to 1 16" less than the thickness of the plank. Leave just enough
material at the back of the seam to prevent epoxy from passing through to the inside.
5. Clean out each seam by running the saw along the batten (Figure 5-1). Check the depth
and width of the cut. Clean out the butt joints at the ends of the plank as well. Chisel a
shallow bevel on the end of the planks (¼" deep × ½" back from the edge) (Figure 5-2).
The bevel increases bonding area and reduces stress at the joint.
A router with a straight fluted bit also will work to clean out seams. Select a bit wide
enough to shave both planks. The router will get into tighter places than the circular
saw, but the bits dull quickly, often break and are expensive to replace.
A chisel can be used in tight spots to carve a “V”
groove where a saw or router will not work. A
scraping or “reefing” tool for cleaning out seams can
be made from a mill file as shown (right) you may
invent your own tool or method for cleaning the
seams. Remember, the object is to clean out the old
caulk and expose clean wood on the facing edge of
each plank for good bonding.
Repairing Hull and Deck Planking 28
Figure 5-1 Use a circular saw to clean out plank seams. Figure 5-2 Cut a bevel on the end of each plank.
Wrap with
duct tape.
Grind the tip
to suit the job.
Heat tang to
bend without
breaking.
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