Is 1” enough? Most of the YouTube videos seem to be saying a minimum of 3 inches?One easy method is a lap joint, which Alcort used. You carefully cut out 1/16th inch with a circular saw on each panel, about 1 inch worth.
Public Lumber in Detroit.Nice! Where's the plywood shop?
Oh, I've scarfed okume plywood together, I'm trying to remember the easy method I found...
This picture gives me hope!!We cut the lap with a small circular saw with several shallow passes. I think I put another piece of ply nearby to keep the saw flat. Then cleaned up the lap with a variety of hand planes and chisels
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I’m now thinking based on the hull, I’m looking at another drive to Detroit to grab two more 1/4” pieces of that lovely 1/4 marine Hydrotek plywood and just practically rebuild this baby. Because I’m a perfectionist and it’s already sold to a family that is so excited to have a beautiful family boat for generations to come."Stacking" like a dado may have moved things too fast. Smaller cuts = smaller "oopsies."
The thumb planes are fun, as are spokeshaves like the vintage Stanley #51.
Just to confound Mama Chicago more, we have also done scarf joints for the plywood, and we used a belt sander...and finished up with a small palm plane. All four hull panels for a Sunfish hull are stacked here and we cut the at one time. A paint finish was planned so sanding and fairing took care of small irregularities. For a bright varnish fish we'd do a lap joint.
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The important thing is to NOT trim the sides or the ends until you have a joint amidships that you are happy with. There is just under 16 feet of panel to play with, remembering that they overlap in the middle. If your first attempt is ugly, sit in the Moaning/Learning Chair for a minute and try again. At one point though, you have to use "Would You Notice the Joint From a Galloping Horse?" criteria and continue on