YouTube Tutorial on Frame Setup
Assembly Table
If your assembly table is flat and true, your board will be as well!
Widths vary with user preference and space limitations - the wider your table the further you must lean to reach the middle - but we recommend building (2) separate panels using kiln-dried framing quality 2" x 4" lumber, surfaced with 1/2" x 4' x 8' sheets of MDF fastened on both the top and bottom. The (2) panels are joined together with 1/2" bolts using washers and nuts. This provides future flexibility for smaller projects and storage.
The table is painted with white primer, which allows the layout lines for the frame sections to show up clear and clean. A carpenter's chalk box is used to snap a centerline along the full length of the table.
Frame Kit
Your frame kit will arrive with sections numbered and ready for assembly. Join the adjacent ends of the spar pieces by (epoxy) gluing and clamping along a marked reference line on one side of the assembly table. Accuracy counts!
Rocker Tabs
The chalk snapped centerline on the assembly table serves as the baseline for registering the rocker profile of the spar. The spar is laid out along this center/baseline, and rocker tab locations are marked, which indicate the position where individual assembly blocks are hot glued. The assembly blocks must all be located on the same side of the line.
Transfer of Cross-Frame Positions
Notches in the spar form the template for the frame section layout. The notch locations are transferred onto the layout table with a well sharpened pencil. Note that you must a pick a side for these notch locations to ensure the best possible frame and spar alignment.
Square the Layout Lines
Use a square to true up the transferred cross-frame positions from the spar to the assembly table. The edge of the assembly table should be square to the centerline. Individual assembly blocks will be glued to the assembly table using these reference lines. Note again to make sure that all the blocks are glued to the same side of the line.
Check Layout
We recommend a "dry-fit" of one frame and assembly block arrangement before committing to final glue-up. This confirms that the spar is "on layout". Use this method at any stage prior to final glue-up, placing the base of the square flat on the assembly table with the blade aligned to the centerline edge. The vertically positioned blade will provide a good check, saving time and effort in the end.
Glue-Up Cross-Frames
After you have confirmed that the spar is in the correct position relative to the layout, dry-fit the cross-frames onto the spar and locate the position of the cross-frame assembly blocks. Hot glue the first five cross-frames into place onto the respective blocks using the rocker tabs. To maintain alignment of the spar as you hot glue the remainder of the cross-frames together with the assembly blocks, sight the entire framework from nose to tail and adjust laterally by utilizing slight clamping pressure against assembly blocks. Proceed one rocker tab at a time to achieve spar alignment.
Once the rocker tabs have been hot glued to the assembly blocks, apply the final (epoxy) glue-up where the cross-frames meet the spar at the notch locations.
Stabilizing Nose
Stabilizing the nose of the board prior to attaching strips to the frame is important. Use a rectangular piece of plywood hot glued to the centerline and lower edge of the spar.
The framework is now fully assembled and glued-up. The next step is the addition of supplemental glue strips.
Please reach out with your questions!
