[Public-List] Re-Sealing the Deck to Hull Joint

[Glenn]

Bob,  i found an easy way to scarf my bulwarks together was to use a cross cut saw to partially cut the eedgesof the gluing surface of the scarf then finish off with a new sharp chisel.  The key to a good scarf is a straight gluing surface and proper ratio between  8:1 up to 12:1 on the first piece, then measure whatever length of cut you have, and lay out the same  distance on the second piece.  cut with a good cross cut saw and chisel the two faces to mate with each other.  A good sharp 1 1/2" wood chisel will make a really clean edge with just a few minutes whittling, and enable you to cut the z ends in place.  If you do have any voids, use epoxy for the glue and thicken with silica or wood flour filler.  Thickened epoxy will fill the joint tight and be super strong. 

When I replaced my toe rails I screwed and bolted the first piece inplace then scarfed the second without securing it to the deck.  Just Used C clamps and a bunch of 2x 3 plywood strips to clamp the joint tight.  Once the glue set up I could bend and bolt the scarfed section into place without worrying about the joint separating.  

There are plenty of good videos on u tube about how to scarf wood, which will help explain how to layout the cut.  If you have any hesitation about cuttting, rip some 2 x3 stock out of an old 2x4  and make up a practise joint or two before cutting into  your teak.  With a good chisel, you will be surprised how easy it is to cut and fit the two pieces together. 

Glenn B
Dolce 318

Sent from my iPad

On Dec 25, 2013, at 3:44 PM, Glenn <brooks.glenn at comcast.net> wrote:

> Bob,  I found an easy way to make a scarf on the toe rail was to just lay out the scarf
> 
> Sent from my iPad
> 
> On Dec 25, 2013, at 1:47 PM, Michael Grosh <dickdurk at gmail.com> wrote:
> 
>> I wasn't able to get that link to open, Bob.
>> So the existing holes are precisely distanced from each other?
>> Michael Grosh
>> #220
>> On Dec 25, 2013 3:53 PM, "Robert Kirk" <isobar at verizon.net> wrote:
>> 
>>>  On 12/23/13, Michael Grosh<dickdurk at gmail.com> wrote:
>>>  "I removed and prepped, filling in the original bolt holes ( I couldn't
>>>  figure out how to get holes in the New teak to line up with the old
>>>  holes)."
>>>  Michael... It's too late for you unless you have to repeat the job or
>>>  have other line-up  related projects, but I was able to reuse the
>>>  original holes by using dowel centers to locate the bolt holes in a
>>>  couple of sections of toe rail I replaced. For example:
>>> 
>>>  http://www.amazon.com/General-Tools-4-Inch-2-Inch-Transfer/dp/B00004T82
>>>  N
>>>  I had to buy a couple of extras do do a usable length in one shot.
>>>  The toughest part of the job was cutting the matching Zee shaped scarf
>>>  joints. I couldn't think of a better way than cutting the Z shape bye
>>>  eye in  the good part of the toe rail, then sacrificing some plywood
>>>  templates trying to match the cutout shape. Any woodworkers with a
>>>  better idea?
>>>  Bob Kirk
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