Jolly Roger-PW Bill of Materials

The following list of materials is intended to be a general guide only. Before ordering any materials, the text and plans should be checked for possible options. All lumber listed as 1" stock is to be standard "lumberyard four-quarter" material which when finished may vary to somewhat less or slightly more than 3/4" in thickness, unless specified as NET. All widths are NET and all lengths allow for cutting to fit. Grouping lumber and purchasing random-random material to resaw to the required size will result in considerable savings. All lumber used should be first grade free from shakes and knots. Although oak (white oak), Sitka spruce, and mahogany (African, Honduras, or Phillipine-dark red varieties) are called out in the listing, lumber typical to the locale and of similar types and weights may be substituted. Long-leaf yellow pine is a good substitute for oak. All plywood (PW) is to be marine (MAR) or exterior (EXT) grade. The marine-type is preferable as the inner cores are solid and thus the panel has more structural integrity. Douglas-fir (DF) is satisfactory with the quality of the exposed faces of the veneer being designated by the letters "A" or "B". The "AA" grade panels are always preferable, however, "AB" grade is acceptable. All plywood should be a minimum of three plies. All fastenings should be bronze or hot dipped galvanized ferrous metal. Brass fastenings are not advised nor are the electroplated screws commonly sold in hardware stores. All screws are to be of the flat head type intended for wood. All nails are of the ring-type nail common to boat construction. Unless otherwise specified, all wood-to-wood joints are to be glued with a waterproof or highly water resistant glue such as plastic resin, resorcinol, epoxy, or other equivalent type used per the manufacturer's instructions regarding temperature, clamping requirements, curing time, and mixing method.
CHECK ALL SIZES TO THE WORK PRIOR TO CUTTING. Abbreviations used are: Mahog = mahogany; SP = Sitka spruce; DF = Douglas-fir; PW=plywood; Ext=exterior; MAR=marine.

ITEM MATERIAL NO.
PCS.
SIZE
LUMBER:
Frames/floor timbers Mahog, Oak or DF 250 r-r* bd ft 2" stock at least 6" in width with some widths up to 12"
Deck beams/deck Mahog, Oak or DF 100 r-r* bd ft 2" stock at least 5" in width with some widths up to 9"
Hatch beams/hatch framing Mahog, Oak or DF 50 r-r* bd ft 1-1/4" stock at least 5" in width with some widths up to 9"
Blocking Mahog, Oak or DF 1 2" x 2" x 8'
Stem Mahog, Oak or DF 1 3" x 12" x 14'
Upper breasthook/transom knee Mahog, Oak or DF 1 2" x 15" x 3'**
Skeg/deadwood Mahog, Oak or DF 100 r-r* bd ft 4" net stock of widths and lengths as required
Keel Mahog, Oak or SP 1
1
2" x 6" x 21'**
1-1/4" x 6" x 21'**
Chine logs Mahog, Oak or DF 2 1-1/4" net x 3" x 28'**
Bottom battens Mahog, Oak or DF 6 1-1/4" x 26'
Motor stringers Mahog, Oak or DF 2 3" x 9" x 10'
Pillow block brace Mahog, Oak or DF 1 2" x 4" x 2'
Cockpit sole/side planking batten Mahog, Oak or SP 2 1-1/4" x 2-1/2" x 30'**
Sheer clamp Mahog, Oak or SP 4 1-1/4" x 2" x 30'**
Bulwark cleats Mahog, Oak or SP 1-1/4" stock sawn to shape, pieced as required
Bulwark clamp Mahog, Oak or DF 2 1-1/4" x 2" x 15'
Cap rail clamp Mahog, Oak or DF 2 1" x 2" x 16'
Deck battens/strongbacks Mahog, Oak or DF 4
2
1
4
2
1
1-1/4" x 2" x 6'
1-1/4" x 2" x 7'
1-1/4" x 2" x 8'
1-1/4" x 3" x 7'
1-1/4" x 3" x 6'
1 1-1/4" x 4" x 3'
Carlings Mahog, Oak or DF 2
2
2" x 4" x 8'
1-1/4" x 4" x 5'
Shelf Mahog, Oak or SP 2 1-1/4" x 3" x 8'
Cabin clamps Mahog, Oak or teak 2
2
1-1/4" x 6" x 8'
1-1/4" x 4" x 3'
Stem cap Mahog, Oak or teak 3 1" x 2" x 15'
Spray rail Mahog, Oak or teak 2 1" x 2" x 28'
Sheer rub rail Mahog, Oak or teak 2 2" x 2" x 30'
Guards Mahog, Oak or teak 2 3" x 3" x 8'
Cap rail Mahog, Oak or teak 1
2
1" x 4" x 12'
1" x 8" x 17'
Bulwark rub rail Mahog, Oak or teak 2 1" x 2-1/2" x 15'
Toerail Mahog, Oak or teak 2 1-1/4" stock sawn 3" wide to match thickness of side handrail
Side hand rail/cockpit rail Mahog, Oak or teak 2
1
1-1/4" x 3" x 17'
1-1/4" x 3" x 12'
PLYWOOD:
Side planking DF MAR AA 2
2
1/2" x 4' x 14'***
1/2" x 4' x 16'***
Bottom planking DF MAR AA 4
12
3/8" x 5' x 10'***
3/8" x 4' x 8'
Bulwark DF MAR AA 1 1/2" x 4' x 16'***
Transom DF MAR AA 1 3/4" x 4' x 10'***
Stem laminations
& gussets
DF Ext AB 2 1/2" x 4' x 8'
Breasthooks, frame
#9 floor timbers
DF Ext AB 1 3/4" x 4' x 4'
Structural bulkheads DF Ext AB 2 3/4" x 4' x 10'***
Decking DF Ext AB 1
2
5
1/2" x 4' x 8'
1/2" x 4' x 12'***
3/4" x 4' x 8'
* All random-random (r-r) is material of varying lengths and widths, the widest possible widths being desirable.
**See instructions for options.
***4' x 8' sheets can be substituted for longer sheets in all cases. Adjust quantities accordingly.
FASTENINGS:
Screws: Flathead wood type, bronze or hot dipped galvanized
  • 1" #8 - 2 gross
  • 1-1/4" #8 - 11 gross
  • 1-1/2" #8 - 8 gross
  • 2" #10 - 9 gross
  • 3" #14 - 2 gross
Nails: Ring type boat nails, bronze or Monel
  • 1-1/4" - 5 pounds

Carriage Bolts: Bronze or hot dipped galvanized complete with nuts and washers. Threaded rod can be used optionally and jamming with nuts.

IMPORTANT: All lengths must be checked to work. See instructions for options.

Glue: Epoxy - 5 gallons



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