dallas2254

For those who have built a Shelly Foss Tug in the past three decades you know this has been a popular tug to have in your marina. I built my first 36 inch Shelly Foss in 1989 and followed that up a few years later with the 45 inch version. I have since found another 45 inch unmolested kit but have not started on it. The real tug is located just 25 minutes from my house.

Four months ago I was reading about the [link=http://www.rcuniverse.com/forum/m_3993444/mpage_9/key_/tm.htm]85 foot Harbor Tug[/link] that Joe had started but what caught my attention was that it was going to be 6 feet long. I had not been building for over 18 years and his build log really inspired me to think bigger than 45 inches. Joe's research provided me the motivation to build the same tug. Problem was, I enjoyed building it so much I knew that it was going to take me far less than a few months to complete so I started looking at my 45 inch Shelly Foss still in the box and thought to myself, why not build a 14:1 scale model, same as the 85 foot Harbor Tug that Joe and I have been building.

I found my set of plans from my 36 inch Foss Tug build 20 years ago and started laying out the parts I would need for scaling it up to 6 feet +. With the help of Martin at [link=https://mraerodesign.securicom.ca/en/products/index.cfm?RubriqueID=26]MR Aerodesign[/link], I was able to put them on a CAD and eventually laser cut many of the parts for the hull and wheel house. I am going to use my 36 inch Darby as my mock up of the original. I recently repainted it and fixed it up to look like the actual Shelly Foss the past few weeks.

Last night the 55 lbs box of plywood arrived from [link=https://mraerodesign.securicom.ca/en/products/index.cfm?RubriqueID=26]Martin[/link] and I spent a few hours inventorying all the parts. To say that I just walked into a candy store would be an understatement. This will be a little more difficult to build. I made plans to cover the hull out of 1/8 plywood but I am also considering planking it with 1/8 balsa strips as I did with the Harbor tug. Ultimately I will put fiber glass cloth and epoxy on the hull.

Tonight I will start laying out the design for the jig to support the hull while I build it to keep it straight and true while I cover it.

One interesting side note, I have noticed that many modern (1970’s and newer) tugs have the same basic hull design with twin screws. This hull would lend itself to many different wheel house layouts. I am already thinking ahead that if this hull turns out good I might have to make multiple different wheel houses and cabins for it or just build more hulls.

For those interested in building a bigger Shelly Foss than what DUMAS has, Contact Martin. He can scale my design to any size you want. I will keep him posted on any improvements to the design as I progress. I have helped him improve upon the 85 harbor tug model plan that he laser cuts. His cost for the plywood and cutting it is very reasonable (assuming your time is worth more than minimum wage and your wife doesn't want you spending too much time in the man cave cutting out all the parts with a jig saw) and he is very easy to work with.

Stay tuned.

Umi_Ryuzuki

See if you can build it up to a stable point by June, then display it at the Bellevue Regatta in Bellevue Park June 5th....
http://nwrcsm.freeyellow.com/index.html

I would love to see it,... sit in it.. paddle around the pond...

Hydro Junkie

Umi, any chance of rescheduling for June 6th? I'd love to see some of the boats actualy running and someone has to give Randy F a hard time

Umi_Ryuzuki

I have no say, let alone any control of what the schedule of the regatta.
And as it is a competition event, the club makes the date annually the first Saturday of
June. That allows everyone some consistency to plan their schedule.

If you can break away, perhaps I will see you there, at least I hope to see Dallas's hull.

Hydro Junkie

Depends on what time the event starts. I have a nonboating event to be at in Arlington at 3:00 so I would be cutting it close either way

dallas2254

I have the frames and stiffiners all cut out and pieced together. Almost ready to glue everything together with epoxy and cloth. Since this is the proto type tug using Martins laser to cut the parts I have been communicating with Martin in refining any parts that need improvements. In another week I should be have the outer hull surfaces together and it will start looking like a shelly foss tug hull.

Kmot

My Feedback: (24)

76" tug. Studly!! [sm=thumbup.gif]

dallas2254

Finished installing all the chines on the fames. Installed Part 15A that wraps around the stern. Used epoxy resin, glass matting to reinforce all seems Part 13A-D) to make the bottom sheeting and spend a couple hours triming an refitting this part. Epoxied the stern to mid section of the bottom sheeting on one side and will finish the front section once cured. To much to do the entire section at once even using 30 minute epoxy since there are so many frames and chines to glue. This also gives the chance to trim the bow section for final fit as this part has the most bending that needs to take place. Not really necessary to steam the 1/8 inch plywood since it is flexible enough for the curves. The stern has the most bending required so I trace the 1/8 plywood pieces to 1/16 plywood and put two layers on the stern as mentioned above.

Hydro Junkie

Just curious, why didn't you just sheet it with 1/16 to begin with and call it good?

Umi_Ryuzuki

I think the parts were all precut in 1/8 by laser.
An issue to forward to the producer.

Hydro Junkie

Just seems to me that 1/16 would be plenty strong considering I build 42+ inch scale hydroplanes out of it, including most of the framing, and they hold up fine at 55+ MPH, including flips and collissions. If you're right, Umi, I would have to agree, time to talk to the producer[sm=wink_smile.gif]

dallas2254

You are absolutely right, 1/16th would be better to work with and I will suggest that to Martin to change on his plans. The only issue is that it is very hard to get 1/16th plywood in big enough sheets to work with on large scale like this boat. The pieces are puzzled together and for 1/16th it would be important to glass the seams on both sides as I have done with the 1/8th size. I bought a few large sheets 12 inches by 48 inches that I used for the stern.

Martin said he has to buy smaller sheets that are twice as expensive and more cutting for the large scale so I went with 1/8th on this tug.

I finished up with the one side of the bottom sheet on the tug this morning before going to work and it came out just fine with some trimming. I did not need to wet the plywood. Just used allot of clamps.

The other issue is that I am using the same plans as the 36 inch Foss tug so at twice that scale I am dealing with frames that are further apart. I do plan on glassing the whole hull so that would strengthen it anyway. If you use just one layer of 1/16th and did not reinforce it with more chines then you might have a flexing problem. With the frames so far apart you also run the risk of getting warping instead of smooth surfaces where the curves of the hull are concerned. That could possibly be eliminated by adding more frames or chines as mentioned.

I vote for 1/16th if it did not require allot more pieces to puzzle together. I am sure it would work.


D

Hydro Junkie

It's possible to get 1/16 ply nin 61X61 sheets. B&D International in Tacoma sells most thicknesses of aircraft grade plywoods in that size. The 1/16 is $57 and the 1/8 is $97 per sheet. Their website is http://bd-international.com/
I've posted a picture just to show how flexible the 1/16 really is

dallas2254

That is really good information on plywood. I would have ordered a few sheets of that 1/16th and just traced my 1/8 patterns on to it but I have already started laying it down on the Frame. I am sure I will be building another tug just like this one and using a different cabin and wheel house so I will be using the 1/16th to see how that goes.

D

dallas2254

Finished the hull and cut the hull off the jig. Built a stand for the hull and started work on the deck.

dallas2254

Fastened the top deck onto the hull, carved the bow block from balsa wood and in the process of installing the hull trim (part #16) around the outed deck above the upper hull sheeting part#15.

Umi_Ryuzuki

It's impressive to be sure... [8D]

Are you going to fiberglass the hull?

dallas2254

I will be fiberglassing the hull with epoxy resin. Working with the 1/8 plywood, prototype plans and alot of grinding and sanding still required a little bondo. I didn't want to use any filler or bondo as I did not use any on the 85 harbor tug, but it was necessary to get and absolutely smooth hull. I am almost finished with the last of the trim around the top of the hull and then it will take a couple yards of fiberglass cloth.

It is very necessary to have lots of clamps and straps for building this model. I have not had to soak any wood to make the bends as you might with the smaller versions of the Shelly Foss. The last part going around the rim of the stern has been the most tricky. Sure could use extra hands. I decided to use 30 minute epoxy since CA and accelarator does not work with out lots of hands. So far very impressed with my own work. I have set my expectations very low so that is not hard to be impressed with my own work.

I really enjoy the creativity involved in building something with no pictures to show you the best way to do it. I should be started with the fiberglassing by week's end. I need to run down to fiberlay in Seattle and buy some more jugs of epoxy resin. Already plowed through 1 gallon between this tug and the 85 foot harbor tug. I bought about 20 yards of 36 inch fine mesh cloth and resin for my truck projects last year so I running off that inventory.

I have already glassed the main deck and will lay one more layer on it to tie in the hull to the deck for a water tight seal. Then I will start building the bulkward around the deck and then the cabin. At this rate I should be done in a few weeks. The first tug took three months and this tug should be 2 months.

D

dallas2254

Stopped by Fiberlay in Seattle today and picked up another gallon of epoxy....over $100. First layer of fiberglass and epoxy is on the hull. This is really a job for two people. Between laying down the fiberglass, mixing multiple batches of Epoxy and working out the bubbles and keeping the cloth straight I was busy. Will sand down and put on about 6 more coats of epoxy.

D

Kmot

My Feedback: (24)

Lookin' good!!

tugs53

Very impressive build[8D][8D][8D][8D]


I'm following the thread closely!!



Mike

dallas2254

Started building the lower cabin on the tug boat this weekend. Fabricated the framing and structure for the lower cabin. Soaked the walls in hot water and bent the 1/8 plywood around the front sides of the cabin. Pilot house is next. I am not going to attach the upper deck and pilot house permantently so I can have access to this vast unused area for electronics.

dallas2254

Working on the pilot house. Need to lower the roof line about 1/2 inch over the pilot house to look like the original.

dallas2254

Bulkwards on, this took a bit of time to cut, trim and fit each side. Glass matted the bulkwards to the hull with epoxy, put on the top cap and sanded. Ready for paint.

dallas2254

Primer and more sanding. Ladders cut and fitted. Getting ready to build the bitts so that they will be strong enough to tow anything. Will not attach anything such as ladders, railings, doors, etc until the hull and Pilot house is painted the Foss colors. As of now I am building the pilot house so that everything is accessible from the outside and inside. The roof of the pilot house will come off and so will the upper deck of the pilot house.

I just went onto various internet candy stores (hobby shops, some in england) and ordered parts from various hobby shops for the tug. Motors, shafts, belt reduction and gears, props, servos, switches, grain of wheat lights (25 of every voltage and size, extra inventory), various colored lamps, wiring, bow thruster unit, push rods, connectors, electronics to run everything on the tug. When you build a 14:1 scale tug boat it seems like the price of everything is ditto.