Tips From A Shipwright

We're back from a short break and boy do we have some exciting news, we've finally found the timber to get started on our biggest project yet, building ORCA! In this episode we head to Bristol Marine to look at an old NOVI so we can get more information about the shape of the hull and other things. Then it's off to New England Naval Timbers to find the right white oak log to start building the centerline. That log will include the keel, the horn timber, and several more parts of the boat. We are looking for material that is clear of the heart and quarter sawn. Next week we're headed back to get the log sawn and then we can take our timbers back to the shop and get started building ORCA!

This week is a big episode for us here at Tips from a Shipwright, we're headed back to New England Naval Timbers to saw up our log and get the keel and more for ORCA! We're buying this log run-of-the-mill that means we pay for the whole log no matter what we get out of it. Our goal is to secure at least one large quarter-sawn timber for the keel but we also expect to get several more large timbers from this same log that will comprise several other pieces of ORCA. We're going to work together with the sawyer to saw this log the way we want so we get just what we're looking for. Lot's of exciting news on our ORCA rebuild project coming soon and we will be returning to our V-Bottom shortly also to flip her over, finish the planking and get her in the water for some sea trials. The fun is just beginning, stay tuned for more!!

Construction on ORCA has begun!!! The first goal for us is to get our centerline set-up. This will consist of the keel, forefoot, stem, stern post and horn timber. ORCA will be 40 feet long and the keel will be just under 30 feet made from two large pieces of white oak. You saw us select and process these timbers at the mill in episodes 1&2. Before we can scarf the pieces together we need to make sure they are exactly square and parralel or the scarf wont match well so we're going to check them with a square and knock it back with the electric place where needed. Now we're ready to make our first plunge cut. There's no easy way to make this cut, especially trying to cut the 2 degree angel so for this first direction I have no choice but to plunge into the material before moving the saw forward. Once we have our two scarfs we're going to connect them and we've got our keel! Our next step is to attach the forefoot to the front of the keel, stay tuned for that and more exciting

It’s full-steam ahead on ORCA!! This week we’re in the drawing room with Lou as he shows us how he’s designing the keel and centerline based on his knowledge of Novi boats which ORCA originally was along with research, study and scaling of many ORCA photos and information. There’s many ways to get involved in the project, we just added a huge list to our website http://www.tipsfromashipwright.com of all the items found onboard ORCA that we will need to complete the boat, from the iconic yellow barrels, to Quint’s fighting chair, his rod and reel, the shark cage, engine, mast, we need it all! So take a look, see what you can find and leave us a comment if you know where we might find it or if you’re interested in helping us make it. More ORCA fun on the way!! Stay tuned!!

This week on ORCA we're assembling our center-line, composed of the keel, forefoot and stem. All this lumber is quarter sawn 6"x6" white oak, so it's incredibly strong and that's what we want for these pieces, especially below the waterline. Today we need to connect and create the scarf joint between the front of the keel and forefoot. We're going to have to plunge cut with our skill saw which is a very technical cut, so we have to set up a backing block to put the saw against as we plunge, well as a guide to follow the line. We're going to make two deep 3" cuts on each side in order to get all the way through the 6" timbers.

We're moving right along with the centerline of ORCA and we're also happy to announce that we have picked up the V-Bottom skiff and will be putting her in the water this week for a test run so stay tuned for that! This week on ORCA, we need to back-up the scarf between our keel and forefoot. To do this we're going to fashion a piece that will span the two other timbers and then be fastened with bronze bolts all the way through to create a strong connection. The rabbit line will then run right through this joint and allow us to set the planking into the keel and forefoot.

The week we're going to drill and connect our entire keel and forefoot together. Drilling can be tricky so we need to take our time to get set up properly. I'm using a barefoot ship auger because it can drill without wandering or pulling and also start off and stay nice and straight. The pieces are going to be temporarily fastened with ready-red or all-thread rod until we are finished with rabbiting the keel and then we'll swap it all out with bronze fastenings later. We're getting close to standing up the entire center line along with the stem and that will give us all a real good look at the shape of ORCA.

Moving forward on ORCA we've almost completed assembling our center-line and this week we're making the final connection between the forefoot and the stem. This joint will be made in a new and improved way that will work to hold the pieces together while also not allowing for any twist. We are ultimately going to be using all bronze fastenings in ORCA because they hold up best and don't disturb the wood around them the way stainless and galvanized fastenings can but we are going to keep the keel mobile for the rabbiting process before then lifting it into place to start framing and planking.

The centerline for ORCA is nearly complete so we're headed back to the saw mill for more lumber. We're out to find pieces for the stern post, horn timber and also our framing stock.

It's time for us to install the stern post for ORCA! This is an important piece as it will have the propeller shaft going through it and it connects the keel to the horn timber above it, which runs all the way back to the transom of the boat. In this episode we're going to show you a little trick to help us mortise our timber into the keel with a chainsaw. Using two wooden guides and some socket wrenches bolted onto the chainsaw to control the depth, we can chew out the material in a fraction of the time it would take us with a hammer and chisel.

This week we're getting out and installing our Horn Timber, the last piece on ORCA's centerline. We first need to cut the timber down to size with a chainsaw so we can get it up on to our shipsaw. The horn timber will run from the top of the stern post all the way to the transom of the boat. We then need to create another mortise and tenon to connect the two pieces, only this time the tenon in the stern post is going to go all the way through our horn timber. Once we chop that hole with our chainsaw we can connect both pieces and we'll have the entire centerline of ORCA together. The next step is making the transom and then rabbiting the entire keel.

It's a new day in the Opendoor Boatshop and we're finally building the transom for ORCA. We first need to lift the lines off our drawing and then transfer them onto our loft floor in full size. Then using a little trick we're going to hammer some nail heads along those lines to copy them onto a cardboard pattern. Simply by pressing the cardboard down on the nails heads we can see the marks on the other side and then cut out the pattern and use it to trace the shape onto our lumber.

We're back building Orca! Getting planking for the transom ready and sharing some hand planning tips for edge setting planks together. Look out for more Orca episode to be released every two weeks alongside additional tips and tricks.

Building the outer framing for the transom of Orca with tips on using bronze fasteners and bedding compound for strong joints.

Adding the inner framework to the Orca transom with a novel joint with stories of mallets and wax balls. Prepping for the next episode where we start to plank.

In this episode of building Orca we walk you through the process of preparing and fitting the first layer of planking onto the transom. From prepping materials, fairing the edges, and fitting all the planks, Lou walks us through the process of building a traditional Maine lobster boat.

In this episode, we take a big step forward in bringing Orca to life. Watch as the transom comes together with freshly prepared planks, carefully aligned and securely screwed into place. Along the way, I share tips for getting a perfect fit, avoiding common mistakes, and making sure everything stays watertight for years to come. This is a satisfying moment in the build — one more piece of Orca locked in and ready for the sea.

In this episode of Tips From The Shipwright, host Lou takes us on a special trip to Tiverton, Rhode Island, for a behind-the-scenes tour of Metal Works, a copper shop known for its craftsmanship and artistry. We explore the shop floor, see the tools and techniques that bring copper to life, and watch as the team cuts out the iconic “ORCA” lettering. Lou is in awe of the magnitude of the machinery and grateful to see a traditional, family-run business still thriving in today’s world. Whether you’re a boat enthusiast, a maker, or just curious about traditional craft in the modern age, this episode shows how history and skilled workmanship come together.

In this episode of Tips From a Shipwright, we finish planking the transom of Orca! Follow along as we walk through the full process of installing and epoxying the second layer of planking using TotalBoat Epoxy. We’ll show the techniques for securing the planks with temporary construction screws, ensuring a tight, clean bond—and then removing them once the epoxy has fully cured. Whether you’re restoring a classic vessel or just love traditional boatbuilding, this episode offers practical tips, clean visuals, and step-by-step instruction straight from the shop.

Lou prepares the lofting floor by laying out a precise grid—an essential first step in accurate boatbuilding. He demonstrates clear, straightforward techniques for striking true straight lines, shows how to establish perfect right angles using the Pythagorean theorem, and shares practical shop tips along the way, including how to properly sharpen a contractor’s pencil for clean, accurate marks.

Lou walks viewers through the working drawings for the boat Orca, explaining how these plans guide the entire build process. Lou breaks down the primary drawing views—Profile, Half-Breadth, and Body Plan—and explains what the various dimensions, reference lines, and notations mean in a real-world boat shop. He also discusses the defining characteristics and overall hull form of classic Novi lobster boats, providing context for the shape and proportions seen in the drawings.

Lou takes the next critical step in the lofting process by transferring the Orca line drawings to the full-sized loft floor. Working at full scale, he carefully pulls and fairs the offset dimensions from the Profile and Half-Breadth views, checking accuracy and flow as the hull geometry comes to life on the floor.

Lou takes the next step in shaping the legendary hull by building Mold #5. This episode dives deep into the precision side of boatbuilding, where accuracy on the loft floor translates directly to the final form. Lou walks through how to properly offset your lines to account for planking thickness, ensuring the finished hull lands exactly where it should. From there, he demonstrates how to transfer those lofted lines onto the mold stock, keeping everything fair and true.