1957 Lyman Runabout – How to Bleach

1957 lyman runabout how to bleach

We have released the 1957 23’ Lyman Runabout’s aft seating, both of the jump seats that John designed and fabricated, and all but the three floor panels beneath the helm station.

Joe D’Avignon, our latest crew member addition, who is also RJ’s brother-in-law, brings years of custom designing cabinets and architectural components, trim and moldings for a firm that executed all tasks using hand tools. Nary a C & C Machine was ever in the shop.

Asked why he wanted to work and grow preserving antique and classic wooden boats, Joe replied, “Unlike windows, doors moldings and the like, where it’s mostly a production process once I designed the piece, with these wooden boats, no two challenges are alike. There are no plans to be reached for, and damn few straight lines. Working at Snake Mountain Boatworks involves everything I love doing in wood without the drudgery of repetition day after day. I can grow here in ways that are just not possible in precision woodworking situations.”

Joe disassembled and sanded all surfaces with 80 grit in a straight line Festool Detail Linear Sander. Each piece in each of the jump seats is unique. Nothing is interchangeable, so Joe’s first question was, “How can do you keep everything straight through the sanding, bleaching, staining and varnishing process?”

A combination of painter’s tape and Sharpies?

Joe, “There must be a better, more permanent but invisible way to do this.

Demonstrating how quickly Joe is becoming an asset for Snake Mountain Boatworks, he found a set of HimaPro wood/metal number and letter stamps on a shelf. Armed with these he proceeded to stamp each piece into the end grain after he sanded it. Voila! Amazon offers this boxed set of stamps. We, as well as folks working on this Lyman in the future will appreciate and benefit from this innovation.

Bleaching with Dalys Wood Finishes A&B Bleach begins this morning. Yes, Dalys is available from Amazon, but we source ours from the company, where you will also find a wealth of useful information.

Among the company’s most critically useful recommendations is, always start from the bottom up, lest you create a sea of white stalactites running down your hullsides and transom that are virtually impossible to erase.

RJ engaged some final helm station component fitting this morning. Next comes releasing the entirety of the new helm station seating and lockers, and then all of the ceilings for final sanding, bleaching, staining, sealing with CPES and varnishing. Welcome aboard Joe!

1957 Lyman Runabout Decking Time

1957 lyman runabout decking

We’ve just begun, but even laying the ribbon-cut mahogany foredeck panels in place foreshadows just how elegant this old style, narrow strake 23’ 1957 Lyman Runabout will be at the end of her conservation.

RJ jokingly predicts that we will have the fore and aft deck panels anchored down by tomorrow afternoon. What he means is temporarily anchored while we complete the final fitting and sanding in around the perimeters of both decks.

We have stabilized the foredeck’s crown with temporary bracing placed vertically in the V-berth. Once both panels are fastened down along all three sides, the curvature of each panel is secure. Bowing them over the framing also shrinks their width. Once there are secured on both sides, there is no way to force either one flat since the edges cannot spread out. Yes, there will be a very slight bit of settling, maybe an eighth of an inch, which is why the crown is currently exaggerated to that same degree.

The perimeters of the foredeck panels will be bedded in 3M 5200 that we spread on the framing and then secured with #6 Frearson head silicon bronze wood screws along both edges and ring shank nails across the dash. We will not sink any fasteners through the body of either panel, which frees us from filing the surface with puttied fastener countersinks.

Doing so is superfluous as bowing the panels over the framing creates ample down pressure, which forces the panels and frames together. (RJ wins the prize: climbing into the V-berth and cleaning all of the 5200 squeeze-out around the frame members.)

I am getting ahead of my skis, however. Once all four panels have been fitted and secured temporally, they will be released. The edges and undersides will be sealed with three coats of Clear Penetrating Epoxy Sealer (CPES), and their undersides will receive multiple coats of Sandusky Paint Company Lyman Sand Tan bilge paint.

The toe rails will follow. After being sanding in to perfect inside and outside contours and their bottom sides are sealed with CPES, they will be installed with ring shank nails.

The aft deck panels and aft end of the king plank will be treated similarly.

Sealing and installing the covering boards, also bedded in 3M5200 will follow.

Once she is fully decked, all of her horizontal surfaces will be bleached, stained and sealed.

Varnishing is next … can’t wait!

1957 Lyman Runabout Endless Staining Begins

1957 lyman runabout staining

We’ve just blasted through a major milestone in our 1957 23’ Lyman Runabout preservation! ALL parts destined for her cockpit have been stripped, fabricated where needed, test-installed, sanded and bleached.

If you watch one of her recent videos again, you might conclude, as others have, that there were very few parts involved.

And I’ve received multiple emails suggesting we were just exaggerating what was involved in creating and fabricating a pair of jump seats and entirely reconceived helm station seating and lockers.

Well, all I can tell you is that RJ, Joe and I were shocked this morning after we had laid all these parts out in preparation for launching into staining them on Monday. Who would have thought!? Staining is next and, as is detailed in the clip, we will use Wood Kote Jel’d stain for this task. (Available from Super F Paint and elsewhere).

From Wood Kote:

Basic Use
Jel’d Stain is formulated for interior wood surfaces such as casework, doors, trim, paneling and cabinets. It matches the corresponding colors of Jel’d Stain 550 & 250 and Liquid Stain 550 & 250. Jel’d Stain may be applied to bare or bleached wood. It is compatible with a variety of other Wood Kote products. Please refer to the Wood Kote Schedule of Product Compatibility and Recommended Dry Times. Jel’d Stain DOES NOT comply with the US Environmental Protection Agency (EPA) Volatile Organic Compound (VOC) emission requirements for Architectural and Industrial Maintenance coatings (effective 13Sep99).

Advantages

  • Matches Jel’d Stain 550 & 250 and Liquid Stain 550 & 250
  • Easy to apply
  • Fast-drying
  • 2-3 times more coverage than liquid stains
  • No stirring required

Coverage
One application of Jel’d Stain will cover approximately 1250-1500 sq. ft./gal (30,6-36,8 m2/L).

Composition & Properties
Jel’d Stain is a fast-drying semitransparent pigment wood stain. It is intended for application without thinning. If thinning is desired, PolySolvent (mineral spirits) should be used or, if regulations require a VOC-exempt thinner, use AceThin (acetone).

Depending upon the boat you own or are preserving, contacting Mike Mayer, Lake Oswego Boat Company ([email protected]) will likely satisfy all of your staining needs. Working with Wood Kote, Mike offers roster of Jel’d stains that match original stains for Pre- and Post-WWII Chris-Crafts, Gar Wood, and many more.

If you are after superior quality and consistent stain, and preserving your vessel as correctly as is possible, Mike is your go-to source. Yes, you can mix stain colors yourself and maybe even save a dollar or ten, but you will also suffer the consequences.

1957 Lyman Runabout Helm Station Fabrication update

1957 lyman runabout helm station fabrication

When we lost him to a heart attack, John had just finished his initial pass at fabricating and installing the new starboard helm station seating and locker.

Save for the copious notes he kept, using the starboard components as templates, and all of the time he spent teaching his methods and skills to his step-son, RJ had precious little to go by. “I’m not nearly as good as John, but I am comfortable doing this.”

The last thing he needed was having me stand looking over his shoulder, so I just worked elsewhere and doing other things like winterizing engines – not my favorite task for sure!

He may not be John’s equal yet, but RJ combined his native talent with all he learned from John to fabricate port helm station seating and locker components that are indistinguishable from John’s on starboard.

Soon we will have a complete set, at which time the fun truly begins. Every bit of her interior must be released, sanded a final time, stained and sealed with three coats of Clear Penetration Epoxy Sealer and scuffed with Scotch Brite pads, before we can begin applying 16-20 coats of Pettit Easypoxy Hi-Build Varnish.

As her owner shared with me, “The grieving process is neither linear nor predictable.” At least RJ and I feel as though we can begin thinking of and remembering John and smile, not grimace!

1957 Lyman Runabout Helm Seating Fabrication Update 2

1957 lyman runabout helm seating fabrication

John has continued living with his “furniture-to-be.” That he’s made great progress is evident from what you will see in the clip.

The helm and passenger seats, and their accompanying lockers will be identical to one another and also as close to being identical to Lyman’s “pass-through” seating configuration as he can get.

He’s matched the radii along the edges, carved an exact copy of the Lyman anchor in the door that are found in original pass-through seating arrangements. We’ve managed to source sufficient OEM Lyman hinges for all moving components, all of which were transformed into jewelry by Mickey Dupuis and his team at D & S Custom Metal Restoration in Holyoke, MA.

But then there are the additional “John” touches, two weep channels in each locker top, additional framing and cleats that are both invisible and add sturdiness to each unit.

Her owners requested that John supply a lip, sort of a toe rail, running along the two outer edges of the locker tops, but only if he could envision and then create profiles that melded with other cockpit components. John did it and the result is both functional and elegant.

And we are working with Pattern Grade genuine mahogany planks that were sawed out of logs that had been graded veneer quality, save for the sides and back, which are ribbon-cut mahogany.

The starboard set should be fabricated and ready for disassembly and finishing by late today or midday tomorrow.

The port unit is next, but John has the starboard unit as his guide, so his “only” challenge is to match what he created there, which he will.

1957 Lyman Runabout -Boarding Step & Jump Seat Fabrication

1957 lyman runabout boarding step jump seat fabrication

Her owners challenged John to design, fabricate and install a pair of boarding steps that are also comfortable jump seat – units for our 1957 23’ Lyman Runabout preservation project.

Sourcing stainless brackets that were strong and worked simply proved to challenging, but Google sent us to www.boatoutfitters.com, who stock stainless steel folding seat brackets that are perfect for this purpose.

We caught up with John about halfway through this challenge. Today’s video celebrates another milestone facing into our wake.

I will allow John to fill in the details and demonstrate his units’ utility and versatility. Now it’s on to the helm station.

1957 Lyman Runabout Jump Seat & Boarding Step

1957 lyman runabout fabricate jump seat boarding step

John is in the process of doing his magic with wood once again.

Her owners challenged him to design and fabricate a pair of folding boarding steps that doubles as jump seats mounted to the 1957 23’ Lyman Runabout’s port and starboard hullsides just aft of the engine box.

As with mocking up the new pass-through helm seating and locker configuration, John reached for cardboard. We left him alone.

That the hullsides are somewhat concave both vertically and horizontally, meant that he could not simply fabricate a matched pair of mahogany wall mounts. The aft mount is thinner; its shape is different, as is the required bevel needed so the mount lands flush against the hullsides. John attacked the port mount early this morning, and by late this afternoon had roughed out a structure that works.

But, rather than steal his fire, I will hand it off to John ….

1957 Lyman Runabout Helm Seating Fabrication Update

1957 lyman runabout helm fabrication

Under John’s eye and steady hands, sheets of half-inch ribbon-cut marine plywood are slowly being transformed into what will be a commodious helm station, complete with a flat floor from the forward end of the engine to the firewall.

That John is in his element, muttering measurements and angles to himself is evident. That he needs his space and wants to be left alone is even more evident. “Helpful” kibitzing is verboten. Prior to launch this slow, exacting process, John and RJ finished fabricating and installing the balance of her new ceilings. With the ceilings in place, John knows precisely the arcs and spaces before him.

It will likely take him the better part of a week to complete the new seating configuring, at which time we must release all of it, including all of the ceilings so they can be finish sanded, bleached, stained and sealed with three coats of Clear Penetrating Epoxy Sealer (CPES). (The lockers will likely be assembled ahead of time so that we can attend to plugging countersinks ahead of bleaching, staining and sealing.

We will apply fifteen coats of Pettit Hi-Build varnish before installing everything for good. We received the final batch of hardware and hinges back from D & S Custom Metal Restoration yesterday.

Shauna Lawrence, Kocian Instruments, expects to ship the preserved gauge cluster in a few weeks. Weather is our major frustration at present. We sourced some beautiful, air-dried Honduran mahogany, which will be transported on an open flatbed trailer. Given the good things that multiple years of air drying has done for the lumber, transporting it through the driving monsoon-like rains we are now suffering is not OK and will not happen.

Looks like a dry window is opening the first half of tomorrow. Guess who will be on the road well before the first glimmer of sunrise emerges over the Green Mountains?

1957 Lyman Runabout How to Mock Up Helm Station Seating

1957 lyman runabout helm station seating mockup

Our 1957 23’ Lyman Runabout’s owners asked us to replace the unworkable, basic helm station seating and storage she was originally fitted out with in Sandusky, OH, with the optional center pass-through alternative.

It will offer a flat floor from the engine box to the firewall, two storage lockers, one behind each “bucket” seat, and additional storage beneath them.

Where to begin? Fortunately the two seating configurations share interior seating pedestals. John began there, shaping and fitting each seat and locker, including the shelves within and the door he will fabricate and install. That door will be fitted out with the traditional Lyman anchor cutout.

John’s ability to imagine and then translate his ideas into a concrete, three-dimensional reality is at least inspiring, if not just a bit intimidating!

1957 Lyman Runabout: How to Fabricate and Install Ceilings

1957 lyman runabout how to fabricate ceilings

Ceilings – hull-side mahogany planking – and helm seating with a center pass-through and storage lockers fixed to the aft side of the forward seatbacks were available options on the 1957 23-foot Lyman Runabouts.

Her original owners opted for the stripped-down configuration, no ceilings and basic seating. The latter included a wide, solid seatback centered in the helm station with two short hinged wings at each end.

Her owners are opting for the upgrades, including a pair of lockers, complete with silhouetted anchors in the doors. Even better, once finished, our optional seating configuration will include a flat floor from stern to firewall, and a small step-up to each helm station seat.

We will fabricate and install the ceilings and mock-up the seating and lockers while her owners are on the east coast. Presenting our concept to them in person helps us reach a joint decision, which must translate into a superior results for all.