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Popular Mechanics 23 Boats You Can Build 1950

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How to Build a Boat

Classic boat plans from a 1937 issue of Popular Mechanics , updated for the 21st century.

It was a long time since anyone in my family had built a boat. The last was my Uncle Paul. He was a shipbuilder who learned his trade beginning at age 14 in Hamburg, Germany. Every morning, the boy rowed from the family's dock out across the shipping lanes of the Elbe River, which flows into the North Sea.

The trip to the shipyard where he was apprenticed took an hour and a half, longer in winter, when there was fog and floating ice on the water. After three years, Paul received a journeyman's certificate and a berth aboard a gigantic four-masted windjammer named Passat—"trade wind" in English. That was in the 1920s, before the fascists confiscated his family's own small shipyard and the Berendsohns left for America.

A few months ago, I decided to try my hand at the ancestral trade. I've built everything from houses to a blacksmith's forge , but there's no more evocative project than a boat, at least to me. Since before Austronesians first gazed across the Pacific, wooden vessels have stood for craftsmanship and the drive to explore. I sifted through PM's archives looking for a classic design and eventually settled on a 10-foot dinghy from our May 1937 issue . It looked elegant, yet simple enough to build on a pair of sawhorses.

It's been many years since my Uncle Paul was around to lend advice, so I ran the drawings past Timo White, a boatbuilder at Tuckerton Seaport, a small maritime museum on the New Jersey coast. It turned out that Timo was in the midst of restoring a surfboard built from plans in the July 1937 issue of PM. (It was a big year for seafaring projects, I guess.)

He confirmed that the dinghy was a good candidate for a first-time builder and agreed to lend a hand if needed.

Shipyard in the Driveway

On a wintry early spring morning I set out for Willard Brothers Woodcutters, a sawmill and lumber dealer in Trenton, N.J. You can spend hours there, roaming stacks of delicious-looking walnut, cherry and oak, some of the boards as wide as your arm is long. I bought red oak for the Sea Scout's frames (that was the name of the craft in the plans, and I chose to keep it) and a 2-inch-thick slab of white oak for the wedge-shaped stem at the bow.

Back home, I started making a racket feeding planks through a table saw. My skills were creaky--I've spent too much time in recent years fixing stuff and not enough building--but over a few days my old confidence returned. The Sea Scout began to take form.

Most boats begin with the frames, the ribs that provide structure to the hull. I roughed them into shape, along with the stem and the gracefully shaped stern wall, or transom, which I cut from ¾-inch plywood. Then I braced it all to a building board--which is nothing more than a 2 x 10 with a chalk line marked down the center.

⚠️ To simplify the project, I omitted the mast and centerboard. Instead, I built the Sea Scout, named after the craft in the original article, to be rowed or powered by an outboard motor. She works well in either configuration. You can find the original plans and materials list here.

The boat's skeleton was in place, but each member still needed to be precisely beveled before I could secure the curved planks of the hull. The next step was to clamp thin strips of wood, called battens, to the frame to stand in for the planks, so I could measure and mark all those angles. Then, I took the parts off the board and finished shaping them.

Often, the weather confined me to the garage, but when the sun emerged I worked in the driveway. If you want to get to know the neighbors, start building a boat. Linda from next door asked whether the craft would be sailed, rowed or powered by an outboard motor. Others wondered where I would go with it, how I'd get it there and what I would name it. A truck driver from Tulnoy Lumber, dropping off some marine plywood, approached respectfully. "This is beautiful," he said, with an old-fashioned New York accent as broad as the hand he ran over the frames.

Anatomy of a Boat

Working the Plank

I don't know how Uncle Paul felt about it, but boatbuilding can be acutely frustrating. The bane of my weekends proved to be a small bronze screw. A No. 6 Frearson flat-head, to be exact. Like most modern DIYers, I'd been spoiled by drywall screws and other aggressive fasteners that practically plow into the lumber. Even using a specialized, tapered drill bit and a waxlike lubricant with the unlikely name of Akempucky, I managed to wreck screws by the dozen. The head on one would strip a moment before the screw was fully seated, while another would shear off on the last eighth of a turn, leaving me with a shiny Frearson-head penny.

Timo had tried to downplay the arcana I'd face--"It's more like house carpentry than fine-furniture building," he had said--but I still found myself floundering on occasion. One challenge was that the 1937 article was more an overview than a detailed set of plans. And, though it pains me to find fault with my forebears at Popular Mechanics, the sketch contained suspicious discrepancies. Timo helped me recalibrate some of the dimensions midway through the project—and I had to trim several pieces after they were assembled.

The biggest hurdle came when it was time to plank the hull. The classic way is to bend strips of solid wood to the frames. I'd chosen marine-grade fir plywood instead to save time, but now I was barely able to force the hull's 14-inch sheets into place. There was no way the half-inch plywood I'd planned for the bottom was going to work.

Timo advised me to switch to a special, wafer-thin marine-grade plywood and plank the bottom in two layers. He came swooping in one Thursday morning to show me the technique. He stepped out of his truck with a broad smile, and a block plane in each hand, and my mood lifted. He politely took a sighting down the chine logs where we'd attach the bottom, and spent a few minutes planing them to the last measure of precision. Then we got to work with staples, glue and screws--and in a couple of hours the project went from a plywood flower bed to a small craft with sensuous compound curves.

It was satisfying, but my mistakes still showed in details like the placement of screws and the shape of the stem. "You know what they say," Timo told me. "Putty and paint makes a boat what it ain't." I got out my paintbrushes.

Maiden Voyage

We launched the boat at Tuckerton Seaport on a cool, overcast day that felt more like September than June. Down at the dock, Timo produced a can of Amstel Light in lieu of champagne. "Go ahead," he said, "pour it over the bow." I popped it open and emptied the beer over the paint. "I christen thee Sea Scout," I said. Then we slid the little craft off the dock and into the water.

You might think a feeling of triumph came over me. Not so. The Sea Scout looked very small, almost helpless, as she sat bobbing at the end of the painter, the little rope that Timo had threaded across the bow. I felt humbled. A phrase from the Book of Psalms flashed in my mind: "They that go down to the sea in ships, that do business on great waters."

I wasn't aiming for any great waters myself. I eased off the dock and into the boat. Timo handed me the oars. Awkwardly, I drew the handles back, just above my hips. The craft slid forward gracefully, almost like she was on ice. As Timo watched, I braced the left oar down in the water and swept the surface with the right. The Sea Scout pivoted neatly, unexpectedly elegant and spry.

If the oars were a kick, you can imagine the thrill I felt when I mounted the 2.5-hp Mercury Marine outboard on the transom. It's a clean-running four-stroke engine, compact yet almost zippy on a boat this small. I gave the engine full throttle and cut some nice straight lines and a pleasingly tight curve complete with a crisp little wake.

With the afternoon gone, my first voyage was complete. In the end, I decided to donate the boat and engine to Tuckerton Seaport. Frankly, I needed the space in my garage and driveway: The Sea Scout was a good first foray into wooden boatbuilding, but I knew I could do better—and I'm already sifting through plans.

The Sea Scout, a Decade Later

Ask anybody who’s ever built a boat, and they’ll tell you one thing about it: you’re not the same after you’ve built one. And that goes for me, too. The little boat, which I built back in 2009, shaped me as much—or perhaps more—than I shaped it.

The Sea Scout project brought a flood of mail from our readers, some of whom had built the boat or knew someone who did. One woman still had the boat that her father built. She sent a picture of it and recalled the many pleasant hours she spent with her dad as her father taught her how to sail in it. She kindly offered to donate the boat to us, thinking that perhaps we could put it in our lobby. I wish I could have taken her up on the offer.

When you build a boat, you take your place in the long line of craftspeople—professional and amateurs alike—who have plied that trade and learned about the unique burden of building a craft upon whom someone’s safety and enjoyment will depend. Building a boat is humbling, you remember every mistake you made building the thing as it bobs up and down, and waves wash over its bow or crash into it from the side.

You feel it shudder, but it doesn’t give way as you look over the side at the murky depths. And afterward, you look at every boat with a more knowing eye, a greater respect...and you wonder if you could build it.

Roy Berendsohn has worked for more than 25 years at Popular Mechanics, where he has written on carpentry, masonry, painting, plumbing, electrical, woodworking, blacksmithing, welding, lawn care, chainsaw use, and outdoor power equipment. When he’s not working on his own house, he volunteers with Sovereign Grace Church doing home repair for families in rural, suburban and urban locations throughout central and southern New Jersey.

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       I’m Arch Davis – I learned boatbuilding and design in New Zealand in the 1970s. I have been helping people to build beautiful wooden boats since 1988. You can see a few of them by clicking on Picture Gallery . My approach to design is to put into your hands the means to use modern materials – marine plywood and epoxy resin – to build a truly lovely boat with classic lines.

      I believe that a boat should be beautiful, not just by virtue of her lines, but also in her construction. No material makes this possible like wood. My aim is to take advantage of wood’s unique strengths, in a structure that captivates the eye. I want you to feel that you are always doing good work in building one of these boats.

       You’ll see that I have a small collection of designs. That is because I understand your need for clear, comprehensible, detailed plans and instructions. I put a lot of time into my drawings, building manuals and DVDs. I also spend a lot of time helping people through their projects, on the phone or by e-mail. I really am here to help!

      If you see something that you like in my collection, please feel free to contact me with any questions. I am available on the phone at 207-930-9873, or email me at [email protected] .

Wooden Boat Plans and Boat Kits by Arch Davis

Grace's Tender - More than just a tender, this little dinghy is a fine vessel in her own right. She is a pleasure to row, and sprightly under her simple sailing rig - a great boat for youngsters to mess about in. Bay Pilot 18 - an 18 ft pilothouse cruiser for outboard power. Laughing Gull - 16 ft self-bailing sailing/rowing skiff. Ace 14 - 14 ft performance daysailer Penobscot 13 - 13 ft little sister to Penobscot 14. Penobscot 14 - 14 ft glued lapstrake sailing/rowing skiff. Penobscot 17 - big sister to the Penobscot 14 Sand Dollar - 11 ft sailing/rowing skiff. Jack Tar - 26 ft plywood lobster boat design Jiffy 9-7 - suitable for rowing or a small outboard motor Jiffy 22 - outboard powered cabin skiff Jiffv V-22 - vee-bottom sister of the Jiffy 22

About My Boat Kits

       I also have epoxy kits and plywood packages for all my designs, plus sails, rigging, and numerous other items. Here's my daughter, Grace, setting up the frames for a Grace's Tender kit.

Please call or write to me at: Arch Davis Design 37 Doak Road Belfast, Maine 04915 Tel:207-930-9873  

If you would like to receive a newsletter from Arch Davis Design, send me an e-mail at [email protected]

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27.3m  /  89'7   custom line   2001 / 2014.

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Vintage Marblehead

In 1930 Roy Clough, then commodore of the Marblehead Model Yacht Club, proposed a new class of larger model sailboats. The first published reference we have is from Model Yachting for Oct–Nov 1930. These boats must be “50 inches on deck” (50 in LOA). The sail area was settled at 800 in 2 , and the single most popular class in the history of model yachting was launched. Called variously the “Marblehead,” “50/800,” or “M” class, it had at one time over 1000 registered boats. The class became a national class in the US in 1932 and an international class in 1937. There were many reasons for its popularity: the size of the boat made for a good sailing model in all kinds of weather and was still (by design, it was rumored) small enough to fit in the back seat of a car. The simplicity of the rules contrasted with the other classes of the day, which required extensive measurement to determine whether a boat was legal.