blue jay sailboat plans

 Redecking a Blue Jay

Part 1 - Fore Deck Structure

It began with that uncomfortable feeling of “something amiss” which takes one when the tongue detects a wiggle in old dental work and the mind is forced to acknowledge movement in something requisitely solid.  From all external vantages the boat appeared sound yet there it was a distinct wiggle at the partners and movement throughout the foredeck structure when the mast was loaded; in the half century’s old wooden Blue Jay, CASPIAN, something was very much amiss.

According to the class rules a Blue Jay’s deck is to be constructed thus: “Waterproof fir or mahogany plywood 1/4" thick…canvassed or glassed” CASPIAN’s deck was certainly ¼” fir, relatively new and glassed (one of the selling points when I purchased her).  However, also according to the rules, “Side decks must be strong enough to lift boat” and the partners “permanently fixed to prevent movement of mast at the deck.” Mine were most definitely NOT.

A Blue Jay is thirteen and a half feet long and removing the wooden glassed over deck meant removing a lot of fiberglass to face screw heads filled with resin--a daunting task.

On all previous boat projects when confronted with old screw removal my method of approach was:  (1) using heat gun & scraper, clean area around the screw head, (2) using heat gun & brad awl, clean out the slots, (3) using screwdriver, try to remove screw, (4) when the slots stripped out, drill off the head and using one of the hollow screw extractors, remove the body of the screw, and (5) epoxy a plug into the hole.  If the body of the screw had enough meat, I would attempt using an “easy-out” in place of the hollow extractor.

It is a method I hated, timely and fraught with risk of damaging the area when, inevitably, the drill bit would run off or miss the shank of the screw.  Certainly I had tried to mitigate the risks, like when facing the refastening of a 60+ year old bronze fastened solid teak deck on a 40’ ketch, I had employed one of those “drill press” attachments on my best Milwaukee 1/2” drill and used a “bit guide”.  Still the old bronze would break away or the drill bit would flex just enough to run out.  Unfortunately it was, quite frankly, the only method I had found which worked.

I began removal of the Blue Jay’s deck with the above process in mind.  Beginning with the smallest deck section, the poop, I stripped enough glass to find the screw patterns, measured the center-to-center spacing with a compass, marked off locations and scrapped the screw sites.  The first couple screws came out ok after clearing the slots and then I hit the drill/extract wall replete with missed shanks and run-outs.  About six screws into the project and I realized I had not enough years left in my life span to deal with all those #8 bronze screws.  True I could cut up the deck, chisel around the fasteners & then get to them with vise-grip pliers, but I really wanted as much of the deck layment as possible for use as template stock.

In the movies, the technique in known as the “flashback”.   OK, here we go... flash back to the summer of 2007, Mystic, Ct, and Wooden Boat Show.  Tool tent.  It was then and there I picked up a set of screw extractors going by the trade name “Grabit” .   Flash ahead now to the winter of 2008/2009.  Those Grabits had been tucked away in their nice little plastic case in my tool bag for some 16 months.  What the h*##, I’d try anything at this point, including another of those shiny wooden boat toys one acquires at boat shows.  One screw, two, three... a hundred.  This thing works, so well, in fact, I began to vary my method.  No longer did I need to clean the slots and after some practice, no longer did I need to scrap around the screw head—as long as a screw could be detected, even under layers of old flaky paint, it could easily be removed and in about the same length of time it took to initially install.

I realize all this rings of infomercial, but I have no association with Grabit other than being a satisfied customer; a single extractor, several hundred screws removed, only one broken head and still going strong. Dare I say “better than grits”?    

‘nough said, back to the Blue Jay.

With the decking removed, some major structural problems, aside from age-failed fasteners, were noted in the method of construction employed in the foredeck.  This in part I think was induced by misinterpretation of the class rules.  The building plans call for 5/4 stock in the mast partner between beams at stations 3-4, 5/4 blocking between beams at stations 2-3 and 5/4 breast hook between stem and an intermediate beam approximately half the distance between the stem & station 1. 

The class rules make specifications as follows:

DECK BEAMS. To be spruce or fir, 7/8" x 1 1/4" or 3/4" x 1 3/8" sided and moulded as shown. Not applicable to fiberglass hulls. DECK. Waterproof fir or mahogany plywood 1/4" thick. Covered with eight (8) ounce canvas or fiberglass, carried down over edge of deck and covered with moulding. Doubling blocks, etc.. must be uncovered only if made of mahogany plywood 1/4" thick, thoroughly painted. Not applicable to fiberglass hulls. Side decks must be strong enough to lift boat. Mast partners are be permanently fixed to prevent movement of mast at the deck. Refer to Section 17a for prohibition of movement of mast during race.

However, and here in, I suspect, lay cause of my troubles, the rules also state, “A king plank may be used on wood boats in lieu of or in conjunction with blocking on the forward deck centerline. King plank must not project more than 1/16" above decking. King plank must not exceed 6" wide (including rabbet) and 3/4" thick.”

Note that the above specifically states blocking, NOT breast hook; in my case the breast hook and intermediate beam as well as the station 2-3 blocking had been omitted in lieu of a 3/4” plank of 5” width.  This was not a king plank in the classic sense as it did not extend above the surface of the deck, its only purpose being to back up the centerline seam of two fore deck sections of plywood.

Additionally, this plank had been let into the beams—in other words the beams were cut away to allow the ¾” plank to lie fully beneath the plywood.  This had the net result of reducing the load bearing section of the beams from 1 and 3/8” to 5/8”—more than half the beam.  In actuality the beams had even been over cut and ¼” shims placed between the plank and beam.  Needless to say all beams had suffered breaks while weakness in the bows due to omission of the breast hook (the plank was toed in to a block screwed to the stem with nothing tying to the hull) was evident from numerous repairs to the stem.

The partners had been cut short, a piece of 3/4 pine screwed to the end and the whole screwed with substandard sized wood screws to beams without glue or bedding—this came out in my hand…

So, where to begin?  Someone once uttered the most profound advice, “begin at the beginning.”   Well, on a boat that might be construed as the bow—so let’s start there.

After stripping all the old paint we begin with a breast hook and intermediate beam per drawing.

The breast hook is bedded in epoxy and tied to the hull and beam with 3” #10 woodscrews.

Working aft from the breast hook, long pipe clamps were set to keep hull shape and one beam at a time was removed and replaced.  Following removal of the old beam, each frame bay was wooded down. The beams and gussets were cut a bit oversized to increase bearing area on the frames and to get into new wood for the fasteners.  The beams were dry fit, then bedded in epoxy and 3 ½” #10 screws run in from the hull. The pipe clamps were left in place until the gustsetswere fit, glued and through bolted.   All then received a healthy dose of red lead primer followed with bilge gray.

In the accompanying pictures a small electric space heater can be seen.  It is my practice when working through New England winters to tent over the boat after setting epoxy joints and run this heater inside the boat.  I tent as small an area as possible and run the heat to maintain about 60 degrees at the epoxy.  This allows the epoxy to be fully kicked by morning.

Partner and blocking beams--full sized blocking per drawings gets fit forward of the partners—it is narrower than the partners to allow fasteners to be reached when installing the partners; however, the fasteners for the block will get covered by the partners, so all must be well & snug.  Shelves have been screwed and glued to the beams and fastener holes drilled and counter-bored.  Fasteners are 5” lag screws.  Blocking and partners bedded in epoxy.

Next installment we’ll look at the side deck and poop structure and look into the steam box.

Affordable Sailboats You Can Build at Home

‍ Key Takeaways

• There are many sailboats that anyone can build from home depending on tastes
• Budget will be the biggest deciding factor on a majority of the process
• Consider kits that come with most of what you need or choose ones that are all-inclusive
• Design complexities and new materials may make the building time process longer
• Plan the best you can ahead of time to save money and your working hours

‍ Buying a sailboat can be expensive, but building your own can save you money. So what are sailboats you can build from home?

Sailboats that you can build from home will likely be a small boat under 20 feet. These could be from many different boat suppliers such as B&B Yachts, Brooks Boat Designs, and Chase Small Craft. Boat plans will vary based on your budget and how much time you have on your hands.

Based on my previous experience, building your own boat will take much longer than if a professional were to do it. You also have to be able to study plans, consider various sailboat designs, and have tons of supplies such as fiberglass tape or fiberglass cloth. On top of that, you will also have to be good with your hands.

Table of contents

‍ Top 10 Affordable Sailboats Anyone Can Build at Home

Building your own pocket cruiser or other styles from boat plans is an impressive feat, as this will need dedicated time and money to assure your boat sails safely. Boat building takes a lot of patience as well, especially since this will not be completed in a fast manner.

Finding boat plans and materials that fit your budget will be key to being able to complete the project. The time it takes to complete these projects will vary on your overall experience and needs. Below are 10 of the most affordable sailboats that you can build in the comfort of your home.

B&B Yachts

B&B Yachts have 14 different boat plans you can choose from to find the boat of your desires. Their shop is located along the Bay River in North Carolina where they construct all of the kits and have a 100 foot dock to show off your project once you complete it.

One popular model to check out is their Core Sound 15, as it is the perfect size for those wanting to build a modest size boat for a handful of people on board. Their website features some videos of completed projects and the plans or kits for purchase.

• 14 different models to choose from plus some dinghies
• Various monohull and multihull options
• Friendly customer service with attractive prices
• Might be too many options for some that are indecisive
• Not ideal for those wanting to have a motor sailer

Brooks Boat Designs

Brooks Boat Designs has a handful of options to consider for your next sailboat building project. They are located in Brookline, Maine and give the option to buy the kits or have them build one from scratch for you. They have plenty of knowledge, so do not be shy to ask about modifications or custom features you are looking for.

Depending on your specifics, they can attempt to accommodate some of their plans to help fit your desired outcome. By checking out their site, you can see many examples of their construction in progress and what the boats will look like when completed.

• Offers a variety of kits
• Plans vary around $50 and up, while materials will obviously add more costs
• Some plans can be rowing boats that can convert to sailboats
• Might take a while to hear back from them, as their contact section is a little outdated
• Their plans may not accommodate a ton of extras for your taste

Chase Small Craft

Chase Small Craft offers a simple process for building boats. Their kits are equipped with everything you need and will help save you time than just buying the materials outright and other parts you could need. This is arguably one of the best bang for buck instances if you want to save time and money searching for pieces to your boat.

They are located in Saco, Maine and will ship everything to your home from there. All the necessary materials are included and all you need are the proper tools and working space.

• All-inclusive kits with what you need
• Tons of knowledge on their site for boat building
• Easy process to order and customize
• Complete kits can range over $20,000 for larger boats
• Kits may take up to eight weeks to ship out

Chesapeake Light Craft

You can expect high-quality boat kits from Chesapeake Light Craft . They feature 18 different sailboat kits that vary from eight to 20 feet in length. This should be more than enough to find one for you if you are newer to boat building.

They also have a wide variety of other kits in addition to the sailboat, in the event that you wanted to order a small kayak or paddleboard in addition to your sailboat. The prices vary considerably when considering a small or larger boat, so check the complete list of options to in order to potentially fit your needs.

• Plenty of sailboat offerings to choose from
• Different beautiful hull form options to consider
• Easy to build and perfect for sailing
• Only has basic materials needed for kit, so you may need to purchase other items
• Has epoxy shipping fee no matter if you pick up item

Dudley Dix Yacht Design

Dudley Dix Yacht Design has an extensive list of plywood and single skin sailing boat options. They have plenty of sail plans and kits to consider depending on your goals. These follow a classic look for sailboats, which are aesthetically pleasing.

If you are wanting one to accommodate a small family, they have more than plenty to look through. The cost is not as bad compared to others, but keep in mind that you may need to throw in your own supplies or specific tools to get the job done.

• Plans start at $30 and range up to $7,500 or more for kits
• More than enough of options to consider
• Affordable variety of sailboat offerings
• Might be too many options for those new to sailing
• Most are wood without the use of aluminum or steel

Farrier Marine

If you are in search of a multihull to build, then Farrier Marine is what you need. They offer a unique folding catamaran that is trailerable and give you the option to build it yourself. This not only makes it an appealing option, but anyone can take this multihull boat wherever they want with ease.

It features a thorough construction guide once you receive all of the materials. These also come with stainless steel fasteners and an aluminum mast for high-quality materials. Pricing will vary since you must request which model type you are considering.

• Ability to build a unique catamaran
• In-depth construction guide to help
• Easily handled and trailerable
• Price may be too high
• Limited offerings since only a few multihull options

Glen-L Marine Designs

Building a boat from Glen-L Marine Designs can save you time and money. They feature an easy system to order and receive the kits, as well as an in-depth guide to building them. This is an appealing option compared to most boat kit sellers.

The beauty about Glen-L is that anyone can build these from scratch, so you do not have to be the best boat builder in the world to get it done. They offer guides and helpful insights from their team to point you in the right direction. Plans vary around $15, while kits can range well over $1,000 depending on boat size.

• Nearly 50 designs to choose from
• Complete guide to help anyone build it
• Plenty of price points depending on size
• Might be overwhelming with the amount of options
• Could take a while to get parts since they are popular

John Welsford Boat Designs

John Welsford Boat Designs invites new and veteran boat builders that want a taste of quality small wooden boats. The boat plans are designed to meet your specifications and are catered to your desires.

There are seven sailboat designs to choose from so you do not feel overwhelmed in the process. However, they do not sell kits all the time, so you would need to have the materials or be on the lookout for the best prices when they are available.

• Seven sailboat plans with different sizes
• Quality boat builder and supporting community
• In-depth knowledge provided to you when you order
• Might be too small of boat size
• Kits are not always available

Iain Oughtred

There are plenty of options on the wooden boat store, but you should narrow down your search for Iain Oughtred’s line of sailboat kits and plans. There are 25 different plans to choose from, which should accommodate most everyone looking to build their own boat.

While they do offer some kits, they do not routinely offer sailboat kits. You would need to purchase all of the materials if you are considering one of their sail plans. Keep this in mind if you are considering, as you would need to hunt down the parts yourself.

• 25 different sailboat plans to look through
• Various sizes to contemplate for you sailing needs
• Prices will vary but are not bad compared to market
• No sailboat kits, only plans
• Newer boat builders might find too many options unappealing

Paul Gartside Boat Builder and Designer

Gartside Boats is a boat builder company based in Long Island, New York that showcases a variety of boats from traditional and newer methods of boat building. Within that variety, they have boat plans meant for six to 50 feet in length.

With an abundance of options, you will need to contact them regarding prices and any customizable options. Kits may vary as well, as they typically design in-house and build for you.

• Experienced boat designer that can accommodate with custom plans
• Many options are trailerable
• Can have plans for up to a 50 foot boat
• You will need to contact them for prices
• Customized options may make process more complicated for new boat builders

How Much Does it Cost to Build a Sailboat at Home?

As you have likely already done so, the math between building your own boat and buying one may be a huge difference. Likewise, you may even enjoy the challenge of taking an older boat that is gutted and restoring with parts from a kit to build one new again.

But how much does it cost exactly to build a boat from the comfort of your own garage or workshop? The prices are going to vary dramatically depending on your situation and material needed to get the job done. In addition, the time that it takes to complete this will also vary.

Sail plans are rather inexpensive if you are aiming to build a small boat. These plans allow you to see the workings of the boat design and what you need to build the boat.

Without these plans, you will not know the exact details of the design and it can cause major issues with the boat’s hull or other areas of the boat. Think of these as the backbone or instructions of the boat’s infancy before being built.

Price Per Square Foot

You should assume to pay anywhere between $300 to $600 per square foot if you are interested in building a boat. Buying a kit outright can be a good way to save time, but oftentimes these do not come with everything you need.

Instead, you should try to source as much of the materials at the best price as possible. Thinking ahead is part of the process and you might be able to score a deal at a lumber yard or hardware store for parts.

Boat Designs Matter

The design of the boat will be much different from one boat to the next, regardless if they are the same size in length. If you are pondering boats that range anywhere between 16 and 20 feet, you should factor in the shape of the hull, any rigging, and various appendages.

Prices tend to increase when there are more complexities within the designs. If you are considering a kit with more details than others, you will also have to pay more for the designs on that as well.

Kits Can Differ

It is important to understand that all kits are not going to be the same. As you gander at sailboat kits online to stitch together, you need to thoroughly look over to see if you have everything you need before buying.

It would also be at your advantage to ask the seller if any additional parts or supplies are needed. This may change your dynamic on the kit buying process and you may pass up one for another if it has everything you need. An all-inclusive kit may cost several hundred, if not thousands, of dollars more to have the convenience of everything in the bundle.

Construction Approaches

Some boat plans may require you to have certain tools to get the job done. This means special saws or planers, which the average person simply does not have.

Purchasing specialty tools might be expensive upfront and hard to find depending on what it is. Your best bet would be to check locally for others trying to sell their tools or consider a boat plan that does not require extensive tools to finish the job.

How Long Does it Take to Build a Sailboat?

An easy to build sailboat could take a while to build from scratch. Many different variances come into play that are difficult to pinpoint for everyone. But how long is that exactly and how will your experience play into this?

A fun project to sail in the wind could take you several months to well over a year depending on the boat plan and how big your boat is going to be. In addition, the materials all need to be accounted for prior to starting in the event a hardware store does not have them in stock.

Time Varies

The time that passes for simple boat designs on small sailing vessels can be done in a few weeks. This is assuming you have everything you need and work non-stop around the clock.

Certain complex situations may make the process long, such as the difficulty of working with some materials. If you are a skilled laborer, it may take you half the time compared to a novice. The amount of time it can take will vary on your availability and skill level.

Planning ahead will undoubtedly offer the most time-saving features. It also helps if you can tackle parts of the project at your own pace.

Complexity of Design

The design of the boat may make the construction process longer. For example, it may take you longer to build a catamaran compared to a similar lengthed monohull.

More complex designs might require more materials, therefore making the process a bit longer to complete. Furthermore, you will also need more experience working with difficult designs and that will affect you more as a newbie.

Be sure to manage your expectations well and do not allow yourself to become too stressed over this fun project. If you can, seek expert boat building advice from a local builder or the company you purchased sail plans through.

Quality Materials

The quality of the materials will matter significantly when building a boat and will greatly affect the time it takes to construct it. Handling fiberglass or carbon fiber might require specialty tools, while wood also demands a certain level of craftsmanship.

If you are not skilled at working with the material at hand, it might affect the quality of the build and you may have to go back to fix mistakes. This will definitely add more time to your project, because mistakes are bound to happen with your first project.

To save time, consider adding the tools and materials throughout the year or as often as your budget allows. You may want to try testing your skills on fiberglass or other materials to get a feel for how to work with it.

Related Articles

Daniel Wade

I've personally had thousands of questions about sailing and sailboats over the years. As I learn and experience sailing, and the community, I share the answers that work and make sense to me, here on Life of Sailing.

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Wednesday, june 26, 2013.

• OD-OY Review - The Blue Jay

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Thursday, October 15, 2015

Blue jay sailboat plans.

The mother of all maritime links: page 16 of 47, Designers, plans & kits a to m: 16' mckenzie river driftboat plans and construction manual (from altair industries) ace marine ltd. (low cost naval architecture. Laser (dinghy) - wikipedia, the free encyclopedia, The international laser class sailboat, also called laser standard and the laser one is a popular one-design class of small sailing dinghy. according to the laser. Building model boats | everyone should enjoy the pleasure, In the early 1960s jay brandon, proprietor of dumas products, tuscon, az, designed and built a scale model of the international star based on the 1945 edition of the.

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Purchasing a used bluejay

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Can anyone fill me in on this boat''s handling characteristics? (I have limited experience.) Also, do you have any hints/tips for inspection prior to purchase? Any ideas about the ideal, small boat, manageable by a woman who''s not into racing---just likes being out on the water?  

I raced Bluejays as a kid. They were the primary Jr. trainer on Long Island Sound. They were typically sailed with crew weights of a couple hundred pounds of less. They were quite weight sensative: too much weight and they were really sluggish, to little weight and they were hard to keep level enough to be competetive enough in a breeze. Even by the standard of the day they were quite heavy and a bit under canvassed and so were considered pretty slow. They pointed OK but were no match for boats like the Flying Jr. or a 420. I don''t think two adults are light enough to race one competitively. I could be wrong but it seems like the older kids began to loose competetiveness at some point and moved on. Still they make nice daysailors for an adult or two and would be fun to own in an envirnment with a bit more breeze than Long Island Sound. BTW: Is your boat wood? Good luck Jeff  

The Blue Jay, designed by Sparkman & Stevens, is still the primary Jr. Trainer on Long Island Sound. We have about 100 of them at a regatta at our club each summer. It is a simple boat that works well as a trainer because it has a main, jib, and spinnaker and requires teamwork from the skipper and crew. Fast Opti sailors who move to the Laser get to the 420 and find themselves surprised by things like jibs, spinnakers, and having to coordinate with someone else in the boat. The Blue Jay''s hard chine and adequate, but not overly generous sailplan makes it a relatively stable platform for learners (quite unlike a 420). An adult will find that the size of the sails makes them easy to handle. If the spinnaker gets messed up, twisted, for example, it''s small enough for to stand up, grab the sail and and untwist. Shorter, (younger) hands would find such a maneuver more difficult. The fact that it is a known quantity means that when its time to sell again, there should be a market for one. Older boats may have leaks around the centerboard. I re-glassed ours this season. The keel can also have problems if the boat''s been trailered a lot or left with water in it on the trailer. (The weight or shock of bouncing on the trailer can damage the keel.) Also make sure the air tanks don''t leak too much. (Check the Blue Jay Class Association Website for more info.) That said, you may find the Blue Jay a bit small for two adults. Something like a Rhodes 19 would give you similar stability, training and resale potential with enough room to invite some friends out with you. You''d also be able to put an engine on a larger boat without totally killing performance. If you look around in your area you will see what boats are there that fit in your niche and suit your needs-- and post again about that one. ely stable ey''re hot suddenly find out  

Hi All I know this an old thread but im about to buy a 1959 bluejay that was garage kept and sailed by the same family since 1963. I was told that some repairs were made by a boat yard around the bottom at the centerboard trunk back in the 80's. it was said that before the repairs the centerboard would have to swell some for the boat to stop leaking? from my research it says you can sail up to four people. that was until I read this thread. im 210 and my son is 40#. for awhile it will be just me sailing the boat. This will be my first boat, I've been searching for several months and when I go to look at the Capri's, and other day sailors they look to be in rough shape. lots of cracked gel coat and worn rigging etc. and look to be to much of a potential project. I'm limited on time and travel when it comes to looking at these boats. im kinda in a rural area near Clear Lake, CA. however this boat looks amazing and its close to me. In Addition to all this I would like to add some type of flotation in case of capsize. and wonder about adding self-bailing ports if possible? and possible NiCad troll motor or a 2hp propane outboard. The boat has documented history, trailer, outboard mount main sail, jibe, and spinnaker, and these present sails where purchased ten years ago. all this for a 1000 bucks. Even better, the owner will rig the boat and go over details with me. Does this sound like a decent deal? Ill be boating on Lake Mendocino which is 3sq miles with winds each afternoon from the pacific ocean. I got the Bug to sail and never skippered a sail boat yet. I'm registered to take lessons down in Sausalito end of the month. And I'm finally a member of Sailnet! #bluejay  

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blue jay mainsail !HELP!

• Thread starter mbjmsx7
• Start date Apr 20, 2010
• Forums for All Owners
• Ask All Sailors

I have recently bought a used blue jay sailboat. I am new to sailing and having some troubles. i was wondering if anyone could post a diagram of where all the lines runs and attach for the mainsail. i have looked all over the web and cannot find one. anyhelp would be greatly appreciated.  

Blue Jay = fun boat. I guess you did not try a google search for 'rigging a sailboat'. This link comes up: http://www.glen-l.com/free-book/rigging-small-sailboats.html Enjoy.  

Yep, the good ol' days! Or was it last spring? It was spring! We bought a boat and didn't have a clue about the lines. One day, my son and I pulled the mast off the boat, laid it on the lawn and deciphered all those buggers. The mast is 28 feet long and must weight 150 lbs. Oy! Well, enjoy all the discoveries that are upcoming. Fair Winds! Don Biddeford, Maine  

RichH beat me to the punch here! I googled Blue Jay and found the same link. Go to specfications on the left and there is a contact name you could try to obtain a owner's manual from. Good luck!  

thanks for the help. best wishes  

Thank you guys for the support. best wishes. Mike, new york  

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