Stapling  
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Stapling is a continuous part of the hull laminating process.

It is suggested in the plans to use full sheets of plywood for the bottom layer towards the stern.  There is then a series of joints where the normal diagonal planks meet the sheet.

At right is shown the seam between the full sheet and the diagonal planks. The starting point of the diagonals was chosen to give good support of the ends on the battens.

The red lines indicate the batten positions and are a great aid in actually making most of the staples hit the battens.

I had tried using stainless staples for fastening to the frames in the hope of leaving them in, but they only get in the way. 

I am using T50 staples and removing them as we progress. The kids are primarily responsible for removing the staples.

For the inner layers I did not use stapling strips.

Here is Jessie demonstrating proper staple loosening technique. Small hammer and modified screwdriver at ~30 angle. Once the staple crown is raised it is pulled with the nippers  shown in the foreground. A large "Channel Lock" style pliers works well also.

Removing each staple this way leaves a nasty dent which is then filled as the next layer goes on if it was into a frame or batten. Holes through all layers between frames must be filled before glue-up of the next layer or the inside of the hull gets covered with nasty glue "zits" which pull off the inner coating when removed!

Current pay scale is 1 to 2 per staple. Curved areas have the stapes set deeper due to greater pressure during application and are harder to remove.

At 1 per staple removed, the cost is approximately the same as the Monel or Stainless staples that would nominally not have to be removed.

At this point, the second layer is started on the bottom. In the lower right corner of the photo, on the side, are 2 faint blue circled areas that are to be filled with fairing compound.  These are low spots. 

At the end of each glue-up session I take the balance of the mixed epoxy and thicken with more micro-balloons to use for fairing or filling staple holes. This way there is then little waste.

Use markers to point out high and low spots as well as staple legs and other defects as you find them. Do not rely on your memory. Remember, fairing is an incremental process and each layer should yield a better (more fair) hull.

Here, David and Elyse are sanding, sweeping and vacuuming up after fairing of the 2nd layer.

Over 15,000 staples so far. We count the empty boxes. The kids got tired of counting individual staples a while ago.

Note: the final staple count is 22,000!

Next: Planking final layer
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This page last updated 06/04/01                        2000, 2001 Mark Bronkalla