One of the goals of the Class Globe 580 program is to provide an inexpensive path to classic "mini for all" performance hull. This means focusing on a few different aspects of the hull and build process. Luckily for us, Don and Janusz manage the design elements. All we need to focus on is the build and outfit/rigging. Outfit and rigging will vary depending on your intended use. If you are looking to do the 2024 Global, outfit and rigging will be more expensive than than those planning a local club racer or pocket cruiser. That means the cost of the "two ends" of our boat building are set by factors out of our control.
The first time builder is likely to find themselves in their shop/shed, looking at a wall/shelf/cabinet of tools thinking "what else do I need". This is where WE have an ability to look for opportunities to control costs. Let me share a little bit of my history, a bit of thinking about of frame based builds, and some thoughts on how we can reduce some costs before we even start our build.
In 2001 my wife and I bought a very old house in upstate New York. As a child and young adult, my father and I did a bit of wood work and home repairs. Seeing a "fixer-upper" the Mrs and I invested in a shop full of semi-professional hardware and I stood up a full fledge furniture shop. While repairing our home I also made pieces of furniture to pay for additional tools and consumables. In 2014 Mrs and I moved to Beaufort, South Carolina coast. When we moved I sold off my shop taking only the tools that I felt would be needed for basic home repairs. That list is not very long
- Sliding, compound miter saw
- Router with D base, traditional base, and plunge base
- Pancake compressor with brad nailers, stapler and pin nailer
- 5" random orbital sander
- Belt sander
- Cordless drill/screw gun
- Hand tools (stiff back saw, rip saw, misc wrenches, block plane, clamps)
Today the Mrs and I rent an apartment in Charleston, South Carolina (where I crew on a J30) during the week. We travel to Beaufort when we can, but we won't be able to move all those tools to Charleston. Nor can I really build 19' (5.8m) boat on the side of the street.
If we look at the blogs for hull #1 and the Setka builds we see that MOST of the frames are built from 22mm (1in nominal) lumber gusseted with marine ply. The length and width of the lumber varies, but from what I've seen the largest width is 62-75mm (3in nominal). The method for joining is to extend one timber through the joint and butt the next timber to the extended section. This GREATLY simplifies the cuts needed by eliminating the need for fractional angles. We simply trace the cutline directly to our timber. My experience tells me that I can hand cut a 1in nominal board with a mid tooth stiff back saw before I can get a miter saw angle set to make the cut.
Looking at the arched tops as shown in the hull #1 build blog, it is tempting to think about bandsaws, jig saws or coping saws. These are all valid options. If we consider the limited amount of wood that actually needs removed (looks to be about 10-30mm or 1in max over 1700mm/60in) we could add a classic method of hand saw, chisel and block plane.
When we start looking at cutting sheet lumber (plywood) we have to look at a couple of other factors. How do we cut curves? How do we manage the size of a sheet relative to our cutting tool? How much space to we have to work safely? A cordless jig saw, a small blade circular say, or fractional HP router with a spiral cut bit would be ideal but very dusty. We will have to use these methods for the large hull panels. For the gussets, a simple coping saw would seem ideal. But most coping saws would not have enough throat to get to the bigger gussets. This is where we use a common yard saw (commonly called a swede, bow or buck saw) with a fine tooth blade.
We will also need a number of small hand tools such as rasps, drill/screw gun (can be brace and hand driver), a sander and a bunch of consumables. As I make the list I will update what tools I'm using and a cost from my local "box hardware" store. While I won't be skimping on tool quality, I will show prices for adequate tools for the consumer.
My target price for purchasing all new tools (I will be bringing some of my home tools to the apartment) will be $500 INCLUDING and electric tools. These tools will be usable long after the hull is built.
Note: the $500 number above does NOT include consumables such as blades, sand paper, etc.