I bought some bronze screws especially to do this job, and a special countersinking bit to ensure a straight and true pilot hole for the screws. Why will the use of screws result in an unfair hull? Should I forget about using them? Confused
Mike, I started looking to use the screws first - before I saw Jacques post. I was going to drill pilot holes so (a) the screw did not bite the side panel and (b) center the screw into the 3/8" frame. After drilling a couple pilots in the frame by hand and trying both course thread and fine thread drywall screws I had, it was pretty clear that either (a) I would not be able to get it centered without some kind of jig and/or drill press and (b) even if I did get it centered, the screw might easily pop out the side if stressed.
I switched with cable ties and it worked great. The hull came out pretty square and was quite and easy to put it all together.
I havent really decided whether or not the stitches will stay or go....probably some of both. I dont think it matters to leave them - or parts of them in since they will be totally covered by epoxy anyway. I kept my holes within about 1/2 of the joint so the fillets will cover the stitch.
One thing that did have me wondering for a while (during the stitch process) was with frame 3 I think it is. When I install all the frames (upside down) I tried to line up the bottom of the frame with the bottom of the side panel. All the frames and hull curves seemed to look pretty good except frame 3 which didnt seem to fit quite as well as the others. I chalked up to being a bit off on a cut, but I think its actually because frame 3 is sized to accomodate the butt block - I bet when I move it 3/8" down it will look better.
The other thing immesley useful, something to keep the transom area together when you stitch the box. I had a couple of 50lb weights - you probably need something equivalent to about 5 gallons of water for each side. I just rested the structure on the ground with a couple 2x4s underneath and that was all I needed.
The only other tricky part was getting it square. I initially had a support under the transom but that was no good. I found one support under each side panel at the transom end and 1 piece under the bow a nice 3 point support for the assembly. I would pick it up at the transom end, jiggle it around and set it down carefully, check for square, tighten up all the stitches. Frankly if it was really out of square - not sure what I would have done.
Good luck!