Big Hunk 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 (dark red Philippine type) are called out in the listing, lumber typical to the locale and of similar types and weights may be substituted. 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:
Frame members/deck
beams
Mahog, Oak or DF 2
3
27
13
1
1" x 4" x 6'
2" x 4" x 9'
2" x 6" x 4'
2" x 6" x 6'
2" x 6" x 7'
Chine logs Mahog, Oak or DF 2 1" net x 2" x 24'
Keel Mahog, Oak or DF 1 1" x 3" x 20'
Inner & outer bottom
battens
Mahog, Oak or DF 1
4
4
1" x 3" x 17'
1" x 3" x 21'
1" x 3" x 18'
Sheer clamps Mahog, Oak or DF 4 1" x 2-1/2" x 29'
Inner sheer clamps Mahog, Oak or DF 2 1" x 2-1/2" x 24'
Knees (*) Mahog, Oak or DF 1 2" x 10" x 8'
Spray rails Mahog, Oak or DF 2 1" x 2" x 25'
Rub rails Mahog, Oak or DF 2
2
2
1" x 2" x 28'
1" x 2" x 27'
1" x 2" x 26'
Stem cap Mahog, Oak or DF 1 1" x 2" x 5'
Transom upright blocking Mahog, Oak or DF 2 2" x 3" x 2'
Frame blocking
(motor well)
Mahog, Oak or DF 2 2" x 3" x 1'-6"
Shaped blocking
(motor well)
Mahog, Oak or DF 2 2" x 6" x 2'
Filler blocking (motor well) Mahog, Oak or DF 1 1" x 3' x 2'
Bevel block (motor well) Mahog, Oak or DF 1 2" x 3" x 2'-3"
Motor well top cleats Mahog, Oak or DF 2 2" x 3" x 4'
Cross brace (motor well) Mahog, Oak or DF 1 2" x 4" x 2'-3"
Blocking at motorboard
knee
Mahog, Oak or DF 2 2" x 4" x 1'
Clamping board
(motor well)
Mahog, Oak or DF 1 1" min. x 6" x 2'-3"
(*) May vary; see instructions.
PLYWOOD:
Transom, lower
breasthook
DF Ext AB 2 3/4" x 4' x 10'**
Gussets DF Ext AB 3 3/4" x 4' x 8'
Stem, upper breasthook,
motorboard & motorbd knees
DF Ext AB 1 3/4" x 4' x 8'
Motor well sides, hatch
& foredeck
DF Ext AB 2 1/2" x 4' x 8'
Bottom planking &
butt blocks
DF Ext or MAR
AB or AA
3 3/4" x 4' x 12'**
Side planking &
butt blocks
DF Ext or MAR
AB or AA
2
2
2
1/2" x 4' x 8'
1/2" x 4' x 10'**
1/2" x 4' x 12'**
** 4' x 8' plywood can be substituted in all cases. Adjust quantities accordingly.
FASTENINGS:
Screws: Flathead wood type, bronze or hot dipped galvanized
  • 1" #8 - 3 gross
  • 1-1/4" #8 - 5 gross
  • 1-1/2" #8 - 4 gross
  • 2" #10 - 7 gross
  • 3" #14 - 1 gross
  • 3-1/2" #18 - 30 total
Nails: Ring type boat nails, bronze or Monel
  • 1-1/4" - 1 pound
  • 1-1/2" - 2 pounds
  • 2" - 5 pounds
Carriage Bolts: Bronze or hot dipped galvanized complete with nuts and washers. Take lengths from work.
  • 5/16" x 8" - 42 required

Glue: Epoxy - 2 gallon



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