1938 Old Town 50# restoration

patrick corry

solo canoeist
See original post on this canoe:

I have been assessing the canoe, stabilizing the shape with some temporary battens in preparation for steam bending approximately 17 new ribs.
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Rib stock is prepared and the steam rig updated with a new burner; I tried the electric wallpaper steamer unit but was disappointed with the results. Besides, it's not nearly as exciting as a loud, open flame for heating several gallons of water!

I came to the conclusion that I would remove the inwales as a unit, cutting all the rib tips at the base of the inwale. Most of the rib tips were damaged in some way, so in this way I avoid all the tip repairs while lowering the sheer only .75". The inwales have had several previous repairs with 'new' material scarfed in, numerous screws installed from the inside out, and other maladies such as this hard spot in the sweep of the inwale at one end. Here, looking at the inwale/deck unit upside down, with a white aluminum sheet placed to accentuate the hard spot: I'm unsure as to how to remedy that un-fair curve. I'll try steaming and attaching to a form. The opposite end has a break in the inwale at the back edge of the deck. That I'll fix with a scarfed-in repair. The previous inwale repairs were not done well, but they are sound for the most part and the screw holes in various places will be drilled out and plugged to strengthen potential weak spots. This canoe is not historically significant, and the owner wants simply to return it to the water for his family as a solid, useable canoe without weaknesses. It was originally equipped with thwarts only (now missing) and I will install seats and a center thwart for family use. I have several pressed-in cane seats, but I wonder when Old Town began using them? For the sake of appearance and my own appreciation for the craft, I will likely hand cane the seats.
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I have several pressed-in cane seats, but I wonder when Old Town began using them?

Hand caned seats were replaced with the pre-woven cane alternative at Old Town as a result of the introduction of minimum wage in the Fair Labor Standards Act of 1938. The transition was gradual as they used up old stock so there are some canoes with hand caned seats that shipped well after that date. The oldest original ones I've seen are in a canoe with serial number 128605 from 1940. The link below has pictures and more details.

Benson


 
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While working on this canoe I noticed that both stems are coved on the leading edges. I hope the pictures convey this. I haven't seen this before, though my experience is limited. I presume it may be a way of avoiding the built-up layer of canvas overlap at the stem. In spite of other failings, this is the first canoe that doesn't have stem tip rot! So, that's a plus!
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It's hard to tell without a ruler for reference, but those stems look fairly wide, and there is evidence of screw holes. I wonder if it had outside stems, even though they are not listed on the BR.
 
Do you think the stems were coved to allow easier attachment of the rubber bumpers?
If you have any pieces of the outwales, I wonder if they got the same treatment?
 
I've also seen this stem treatment on Old Towns, but cannot remember the details - maybe on canoes with outside stems as Dan suggested. This would allow overlapping canvas and tacks to still provide a flat surface for attachment of the outside stem.
 
I carved out a pair of outside stems I made recently to match the damaged original ones.
As is noted, the carve out gives relief for the canvas fold, tacks and bedding compound.
Given a choice of digging out material from the stem, or from outside stems, I think I prefer to see it done on the outside stems.
I dislike the idea of removing wood from the stems.
The outside stems are a more easily replaceable part.
 
You gents are wicked smart! Working on two 50# at the same time, I had forgotten that this one- as noted on the build sheet- had outside stems. Pictured are the stems; slightly coved inside the arc until the hull runs flat at the base of the stems.

Here the coved portion of the stem runs out to flat where I'm pointing.

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Width of the stem at the top:
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Outside stems"
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Width at base:
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Width at top:
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I'm scarfing in a repair piece which joins the inwale to the rear deck which requires a sweep up to the deck plane, so the Spruce repair piece with scarf cut and deck joint angle already cut is steam bent here. I didn't need the full arc of the form (from a previous project) so the bend shown should be enough.

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Inwale repairs continue...

Stern starboard repair rough shaped and glued in place on the inwale side; once fully shaped and sanded the other end will be screwed into the deck.
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Looking over the entire inwale/deck assembly I discovered another fault at the bow/starboard side. The inwale is cracked through above the screw at the rear of the deck: only the wood fibers below the screw were intact.
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New repair scarfed and glued in. It was made from the scrap left over from the previous repair and therefore had the correct upsweep. Just my luck- there was no advance planning there!
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The final inwale repair (aside from drilling/pegging the unwanted old screw holes) will be straightening the 'unfair' sweep of the bow/port inwale pictured earlier.
 
Inwale scarfs complete. I have found this Japanese ryoba saw very handy for working on canoes. Very thin kerf and pull rather than push cutting seems to work better on hard to hold down parts.
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Both end repairs:
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