Building Melanesia
Melanesia is a 16' outrigger canoe designed by James Wharram. Plans are available for sail and paddle versions; I purchased the package that has both. The main canoe is built of plywood using the stitch-and-glue technique. The outrigger, beams, and spars are made from bush materials. The primary difference between the sail and paddle versions (other than the obvious lack of a sail) is the size and placement of the outrigger. The sail version needs a much larger float placed much farther outboard for stability.
I ordered plans for Melanesia on March 26, 2007. Shipping from the UK to Illinois took a few days. The plans are much more detailed than I had expected. In addition to four A1 drawing sheets (approximately D size), there is a relatively thick book of detailed instructions, including many fold-out A3 (approximately B size) drawings.
I searched in vain for a local supplier of marine plywood. There just isn't much call for boat-building supplies in central Illinois. I was able to find marine plywood as thin as 3/8", but not 1/4". I finally settled on Plyfloor. At Menard's, 1/4" birch cabinet-grade plywood was right next to 1/4" birch Plyfloor. I am optimistic that it will be an acceptable substitute, at least for a boat of this size that is stored out of the weather. It has one good side, which I'm putting to the outside of the boat. I chose a local plywood rather than ordering marine plywood for two reasons. One, it was much cheaper, particularly when shipping was included. Those who say the cost difference between marine plywood and other types is minor must not be paying $99 shipping per order. Two, if I screw up, I can just run to Menard's and buy another sheet.
I decided to go with MAS epoxy. I ordered it from Chesapeak Light Craft. I almost ordered plywood from them as well. Other web sites with similar product offerings are Noah's Marine Supplies, Goosebay Sawmill & Lumber, Inc., and Clark Craft.
Our family is going on vacation on July 9. My goal is to have the main canoe completed by then. I fear that the rest of the construction will take as much time as I'm willing to spend—at what point will the outrigger be good enough? Finishing (sanding, fairing, painting) can be an infinite time sink.
This page summarizes important project information. A timeline captures daily, weekly, monthly progress.