The Tedious Tale of Zip Frame #2 — part four

After installing the shims, it was time to shape the floor member of Frame #2 to its proper dimensions. 

This took a while. I used a Stanley Surform plane and a sanding block, working a little at a time. I frequently checked my progress against the construction drawings. I also used a straight edge to ensure that the surface was straight.

Shaping the floor beam

Once that was done, I drew out the gussets on scrap pieces of 1/4" Meranti plywood.

Drawing out the gussets

Once the gussets were cut and sanded, it did not take long to have the frame 3/4 assembled. I still need to epoxy all these parts together. Then, as with Frame #4, this frame will have to wait until I buy another mahogany board or two for the deck beam.

Lap joint with single gusset, just like Frame #4

Chine notch cut with a saw. (Note that I may need to add a shim to the end of the floor beam.)