Greetings all, I hope to bend and install some of the ribs in the next few days and in the course of studying up on the process it appears there are two methods. One being to do the preliminary bend (outside) and then proceed right to the install with the still hot rib. The other is to leave the preliminary bend clamped in place (outside) and do the install after the rib has set overnight or therabouts. The later seems to be the most popular.
Actually I have enough ribs to do to try both but it's cold out there in the shop and I'd obviously like to go with the best chance of success. Your collective experience would be greatly appreciated. Cheers, Fred
Just finished the bending process yesterday and I'm just now taking a break before nailing in the last rib.
I had/have to replace 4 mid section ribs. I got a hold of some flat sawn white cedar boards that had been in the rafters for at least three hot summers - they were the lightest planks I ever handled. I took a full thickness plank, ripped it to 2 3/8 inches wide, and ran both faces over the jointer (don't care if they are parrellel or not) I laid out the rib tapers, cut them on the bandsaw, planed it fair with a couple swipes of the block plane.
With a 22 degree bevel bit in the router, I beveled all four edges with the bearing running along the edge
I then set the fence on my band saw for 5/16 and running the milled faces against the fence, I cut two ribs from this prepared plank.
I constructed a steam box using 1 x 6 pine screwed edge to edge with drywall screws and a square plug in one end with a hole for a radiator hose. The other end of the hose is shoved into the end of my tea kettle which is placed on a coleman stove. I stuck a meat thermometer through a hole drilled in the far end of the box. I loaded the rib blanks into this box, stuffed the open end lightly with rags and fired it up. I accomplished 200 degrees inside the box at 15 degrees F.
While the ribs were cooking, I plugged in a steam iron, got a bucket of water with a rag in case I needed to apply some extra convincing during the bending process.
This is the critical part ( how I screwed up) : Because they were mid section ribs,
I counted 3 1/2 rib spaces towards the end as the point over which to bend the ribs. Through the screw holes which had affixed the keel to the bottom, I screwed a bridge to keep the midsection of the rib from lifting off the bottom as I bent the rib around the bilges.
After 20 minutes I pulled the rib blanks from the steam box, slid them under the bridge and slowly wrapped them around the bilges one side at a time holding them against the gunwhale with spring clamps. By the time I got to the other side of the boat, it was bending a little stiffer so I used the hot steam iron and rag to bring the rib against the boat in a sizzle of hot steam.
I left them for a couple days until I could get back to them and eventually nailed the first two into the boat.
Here's where i screwed up. The Old town is curvy enough that 3 1/2 frames was too far. The turn of the bilge at that point is not as sharp and it is significantly enough narrower that it didn't fully span the mid section before starting the turn. The ribs had enough flex that i could span the rib end and inwhale with a clamp and shove it into the turn of the bilge. After I had it nailed in and the boat rolled back over i noticed that the planking wasn't running particularly fair through that section - not enough to redo but enough to annoy me. A week later, I noticed that the two ribs i had replaced had cracked right at the turn of the bilge.
I was delighted cause now i could make them go away
I figure between the dry dry wood, hot iron and forcing the fit, the cedar couldn't take it. I'm glad it happened before the canvas went on.
Since more varnish had been removed since those ribs had gone in, i noticed the cracks in the 3rd and 4th ribs.
So I milled up 4 new blanks from the same cedar stock, wrapped them in a wet towel and propped them in the corner of the shower. The towel was kept soaking wet over the better part of a week
Yesterday I re-affixed a bridge, this time only two frame spaces away from the ribs being replaced.
I used the same steaming methods, colder day, but still cooked them at 200 degrees for 20 minutes
They wrapped around the boat like butter and lay nice and flat against the hull
This morning I split out the new but cracked ribs and the subtle humps melted away. The newly bent ribs jumped right in, nestled into their places and fastened easily. The hull remains fair.
All of this was extraordinarily simple to do - once the correct location for bending the rib was identified.