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Old 08-12-2011 | 07:51 AM
  #13  
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Hydro Junkie
 
Joined: Nov 2004
Posts: 10,629
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From: Marysville, WA
Default RE: Re-Engineering A Dumas Pay'N Pak

The cowl and bow blocking has probably been the hardest part of the build. The cowl build started with fabricating a cockpit rear panel, part 7A in the kit. Tracing this part was not possible due to the wider width of the engine bay so, using dimensions from the kit supplied part, a wider one was fabricated. I then traced around the tail doublers and lower cowl sides and cut them out of 1/32 ply. To get the tails to the desired width up to the back of the cockpit, I fabricated a framework using 1/8" thick spruce stick stock with widths of up to 1/4" to fill out the tail and sidewall thickness. The vertical tail frames were then sanded to get a scale like taper along the rear edge of the tails. The precut skins were then glued to the inboard side of the vertical tails. The tails were then glued to a false floor that comprised the deck between the tails as well as the cockpit rear panel. To get the front of the cockpit width, I again turned to the Newton color sheet as well as pictures of the full sized Pak to make the new part 5A. I then glued a 1/8" square piece of stick stock to the outside of the tail framing, cockpit rear and the newly fabricated 5A, tapering the rear to get the right angle to the cockpit side. New frame upper halfs were fabricated using the height of the kit parts but with the widths adjusted to the wider engine bay. I now moved to the front of the hull and fabricated a nose cowl bottom block, adjusting the width and shape to match the wider profile and attached it to the front of frame 1. Before going further on the cowl, I added 1/8" glue blocks to all the vertical and top edges to assist in holding the skin. I now installed the lower cowl sides from tail to the front of the center nose block. I next attached glue rails along the top of the cowl frames on both sides to attach the cowl top and upper cockpit sides. At this point, the boat was starting to show that it actually was going to look somewhat like the Pak from the kit.
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