For Love of Imperfections: Huron Canoes and Terry-Thomas
February 7, 2010
What do Terry-Thomas and Huron Canoes have in common? Forgive me for making an obscure cinematic reference to talk about wood-canvas canoes, but that’s just the way my mind works.
As a kid in the 1960’s, I loved watching movies on TV. Amongst my favourites were odd-ball British comedies – many of which featured Terry-Thomas. Besides his impeccable comic timing and outlandish accent, his claim to fame was evident every time he smiled. Terry-Thomas made a career out of a feature that many people would try to hide or get rid of altogether. He played off of his imperfections and we all learned to love “The Gap” – a space between his front teeth you could drive a truck (or should I say lorry) through. The gap in his teeth was what made Terry-Thomas Terry-Thomas. Without it, he loses much of his quirky comic charm.
It is not uncommon for me to get an anxious e-mail from someone who wants to know what to do about all the wide spaces between the planks in their Huron Canoe. They complain that some of the gaps are as much as ¼” wide. The main worry is that water will seep through the cracks and get trapped between the hull and the canvas resulting in damage to the canvas over the long-term.

In his attempts to "fill the gaps", the owner of this canoe threw everything he had at it. By the time he finished using silicon, epoxy and varnish, I was hard pressed to see any wood in the canoe.
Some people interpret the gaps as damage to the canoe that has to be “fixed”. I have restored Huron canoes that people have attempted to “make water-tight”. They fill the gaps with everything from silicon to epoxy and varnish (and sometimes all three). Of course, all it does is make more work for the poor sole doing the restoration.

This Peterborough cedar strip canoe from 1921 is a wonderful display of craftsmanship. Building a hull like this required a great deal of time and skill. The use of canvas removed the need for water-tight planking in the canoe's hull thereby reducing the skill and time required to mass-produce canoes.
The whole idea in covering the canoe with canvas was to allow the production process to be faster. The builders didn’t have to worry about a tight fit in the planking because the filled and painted canvas made the canoe waterproof. Since the builders were not concerned about creating a water-tight hull, they were able to plank the canoe in a third the time required to construct an all-wood hull (for example, Peterborough Canoe Company cedar strip canoes).
As mentioned in last week’s blog article, water contacting the canvas from the inside is not a major threat as far as the longevity of the canvas is concerned. As long as the canoe is stored: 1) off the ground; 2) upside-down; 3) under cover; 4) in a cool space; 5) with good air circulation, the canvas will last for several decades before rot sets in.
Granted, Huron Canoes are a little rougher than average, which is precisely what I find appealing about them. The gaps have absolutely no effect on the waterproof nature of the finished canoe. The only real affect the gaps have on the canoe is a slightly rougher final finish when the canvas is painted. However, just as with Terry-Thomas, the imperfections are what make Huron Canoes Huron Canoes.
If you have any concerns about the gaps between the planks in your Huron, I encourage you to accept it for what it is. Embrace the gaps as part of what makes these canoes instantly recognizable. Personally, I love the imperfect woodworking in Huron Canoes. I also love the way they handle in the water – a true delight.
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Preventing and Repairing Rot in Wood-Canvas Canoes
January 31, 2010
Wood-canvas canoes, by their very nature, are subject to rot. The problem is not entirely avoidable, but can be reduced. Once every thirty years or so, damaged areas can be repaired.
Wood rot is caused by a number of fungi (Serpula lacrimans, Poria incrassata and Gleophyllum trabeum are among the most common). The results turn solid wood brown and crumbly. As you disassemble the canoe for inspection, affected areas break apart into cubes when disturbed.
These fungal spores are present almost constantly, but can only grow when certain conditions are present. Wood rot fungi need three basic ingredients in order to grow: 1) water; 2) no air circulation; 3) a warm environment.
Parts of your canoe (such as the canvas under the outwales, stem-tops, rib-tops and inwale-ends) are normally covered and protected. If these areas are allowed to stay warm and wet, they become prime environments for fungal growth – in other words, rot heaven.

Proper canoe storage prevents rot from attacking wood-canvas canoes. These canoes are stored off the ground, upside-down in a cool enclosure with lots of air circulation. The rack braces are built from 2x4 lumber while the racks are standard 1" steel pipe threaded through 3-foot sections of ABS pipe that act as rollers to ease loading and removal.
To prevent rot from forming in your canoe, store it upside-down off the ground in a cool place that has lots of air circulation. A lean-to shelter next to the house makes an excellent canoe storage area as does a carport.
Proper storage of your canoe goes a long way to preventing rot. Another step is to maintain the exposed wood with a fresh coat of spar varnish every year or two. Spar varnish seals the wood and shields it from the invasion of water and fungal spores. It is made by cooking an oil (usually tung oil, linseed oil or soybean oil) with a resin (usually an alkyd). If used straight from the can, the high proportion of solids (resin) in the varnish result in a finish full of brush marks, bubbles and sags because it takes a long time for it to cure. In order to get an even finish, varnish must be thinned with mineral spirits prior to application in order to reduce the curing time. I add about one part paint thinner to seven or eight parts varnish (½ cup – 125 ml - thinner to a quart – 950 ml - of varnish). In some high quality spar varnishes, more thinner is required to get the desired curing time. Some manufacturers confuse the issue by selling products under a variety of names such as “Oil Finish”, “Wiping Varnish” or “Danish Oil”. These are nothing more than thinned varnish.
When restoring your canoe, a number of things can be done to both repair the damage and prevent rot from developing in the future.
First, use an epoxy sealer to harden the wood in areas that are either already affected by rot or likely to rot at some point. These sealers are either one-part wood hardeners or two-part epoxy sealers. The fumes from these products are highly noxious, so be sure to wear a proper respirator.
Areas already rotted will break away and must be cut away before starting repairs. Once you are back to solid wood, scarf in new wood and rebuild the affected area.
Once the repairs are complete, apply a combination of boiled linseed oil and turpentine to all exposed wood. Linseed oil soaks into the wood and prevents water from absorbing into the canoe every time you take it out for a paddle. I mix about one part turpentine to three parts oil. A little note here: boiled linseed oil isn’t actually boiled. It simply has drying agents added which allow the oil to dry in a couple of weeks. If you used raw linseed oil, it would take a few decades to dry. The application of linseed oil doesn’t stop water absorption completely, but it is a great preventative measure.
Check out Kettle River Canoes.
Installing New Inwales in a Chestnut Prospector Wood-Canvas Canoe
January 25, 2010
Attaching new outwales to a wood canvas canoe is not a particularly difficult or complex task. However, there is a debate about the timing of this part of the process. Do you attach the outwales before or after the canvas is painted? The short, and somewhat cheeky, answer is: “Yes”.
When these canoes were mass-produced in large factories, the builders attached the outwales to the canoe as soon as the filler had dried. They would then applied paint and varnish to complete the canoe. The order of events had more to do with efficiency than anything else. The disadvantage was that the canvas under the outwales was left unprotected by paint. In the long run, even though the lead in the filler helped prevent rot, water would become trapped under the outwales. This damp, confined area eventually becomes a prime environment for rot. When people bring their canoe to me for re-canvassing, the canvas has usually rotted along the sheer line under the outwales.
Since I don’t use lead in my filler, I prefer to protect all of the canvas with paint before the outwales are attached. Some builders, like Jack Hurley in Dwight, Ontario, go the extra mile and apply varnish to the cut edge of the canvas before the outwales are attached. Painting and varnishing before the outwales are attached, protects the outwales from rot. I also apply shellac and varnish to the inside surface of the outwales. The bottom line is that the more you protect wood and canvas from water that will inevitably become trapped, the more you protect your canoe from rot. It is not a guarantee, but it all helps. Since you are not under the gun of a production schedule, you can take the time to seal surfaces that would otherwise be left unprotected.
Once you have finished painting the canvas, put a new blade into your utility knife and trim the canvas flush with the top of planking. In most canoes, this is ¼” below the rib-tops. In Huron canoes, this is flush with the rib-tops as well as the top of the sheer line planking. Take your time doing this. It is best to err on the side of caution the first time around the canoe by cutting high and then trim exactly the second time around. It is very easy to cut the canvas below the top of the sheer line planking. You want to avoid this at all costs, so take your time.
New outwales are made of hardwood. Usually they are the same as the original outwales which is normally either ash or mahogany. One the are varnished and ready for installation, I put small pieces of masking tape on the top surface of the inwales to mark the locations of the screws that will hold the outwales to the canoe. For the first four feet or so at each end of the canoe, screws are used at every second rib. In the central body of the canoe, screws are placed at every third rib. I mark the screw locations ahead of time to speed up the process later. It also allows me to ensure that the screw locations are the same on both sides of the canoe.
I start by making sure the outwale will cover the entire side of the canoe once it is in place. I clamp the outwale at the centre. I then use a hardwood mallet to tap the outwale so that the top surface is flush with that of the inwale.
Be sure that the canvas is held smoothly against the hull as the outwale is clamped into place. Trim it where necessary to create a canvas free of bulges or creases along the sheer line.
Pre-drill a pilot hole for the screw and counter-sink the hole so the screw will be secured below the surface of the outwale. I use a combination drill bit and counter-sink to do this in one operation. I centre this hole on the outwale (top to bottom) and centre it with the rib as well. Throughout the rebuilding of the hull, I do my best to keep the central area of the rib-top free of fasteners. When, as inevitably happens at least once in a canoe, I hit a fastener as I drill the pilot hole, I angle the hole slightly to create a clear path for the screw.
Use silicon-bronze screws (#8 – 1½” flat head) to attach the outwale to the canoe. Often, I am able to re-use the original screws. I save them when I disassemble the canoe because they are usually in very good condition. Normally, these screws are square-drive (Robertson) screws. When installing Greenwood or Old Town canoes, some clients insist that I use slot screws to match the originals. However, I find them so much more difficult to use, I tend to use Robertson screws wherever possible. A little side-note here: my cousin Patricia Elliott (nee Robertson) was the daughter of Peter Robertson, who invented the Robertson screw in 1908.
In most canoes, the sheer line sweeps up from the centre of the canoe to the ends in an even, graceful arc. As a result, the outwale is attached with little difficulty. In canoes such as the Chestnut Pal or the Peterborough Champlain, the outwales must be pre-bent over custom-built forms and pre-fitted to match the sharp up-turn in the sheer line about 18” from the ends of the canoe. Fortunately, none of that is necessary in this Chestnut Prospector.
When the outwale is attached, use a sliding bevel to mark the angle in the cut-off at the ends. Trim the ends. I use a Japanese utility saw (14 tpi) that cuts on the pull stroke. Sand the ends smooth, then stain and varnish. I also take the time to stain and varnish the newly exposed wood in all of the screw holes. This is one of those little details that transform the project from great to spectacular.
Check out Kettle River Canoes.
Installing Original Stem-Bands in a Wood-Canvas Canoe
January 17, 2010
Nobody wants a leaky canoe. So, when you come to re-install the stem-bands, bring your full attention to the task. Mind you, when restoring a canoe, this is nothing new.
The stem-bands are strips of half-oval metal used to protect the canvas seam along the outside face of the stems. They are usually made of brass, but I have seen copper and aluminum used as well.
Brass is a combination of copper and zinc. Most brass available today is about 63% copper and 37% zinc. It is easy to bend when cold. Original brass stem-bands, by comparison, contain about 69% copper, 1% tin and 30% zinc. The addition of tin helps prevent the alloy from losing zinc when exposed to water for extended periods. It is commonly referred to as naval brass.
Original brass stem-bands tend to be harder, heavier and when cold, more likely to break when bent. Care must be taken when handling them. The metal is very thin around the drilled and counter-sunk holes, so original stem-bands are easy to break.
Start the installation process by pre-fitting the stem-bands to the canoe. Since they are being reattached in their original locations, they ought to sit nicely in place. However, if the stem-band has been kinked or requires substantial bending to fit the canoe, use a propane torch to heat the metal before it is bent to fit. Once the stem-band is back to the desired shape, quench the metal quickly with lots of water.
When installing original stem-bands on a canoe with new canvas, cut the canvas back from the stem at the top of the planking. This gives you access to the stem-top. I put a new blade in my utility knife and cut back about 2”.
With a putty knife apply a Marine Bedding Compound evenly to the inside surface of the stem-band. This seals the area and prevents water from leaking in through the holes that are drilled along the stem. I use Dolphinite which is an old-style, linseed oil-based compound that doesn’t harden. I apply it right up to the top of the stem leaving bare the section of stem-band that runs along the top of the inwales to the deck.
Centre the end of the stem-band on the deck and drill a hole for the screw. Huron stem-bands are ½” wide and use #6 screws while most other builders used 3/8” wide stem-bands and #4 screws.
Attach the top end of the stem-band to the deck. I do a test hole in a scrap piece of hardwood to ensure that it is the correct size. If the hole is too small, the silicon-bronze screws will snap as you attempt to screw them into the wood. Too large, and the screws will pull out.
As you attach the stem-band, you must first centre it on the stem. Then use a wooden mallet to flatten the band to the stem. Since the stem-band has been pre-fit, the amount of cold bending done at this stage is of little concern.
For each hole along the stem-band, pre-drill and screw into place. From time to time, you may encounter a brass tack along the stem. If so, drill through it with a slow turn rate until the bit cuts through the tack. Then continue with the regular drill speed. For most locations along the stem-band, the screws are ¾” long. Along the bottom of the canoe, you may feel the drill hit a space between the canvas and the stem. In this case, use a 1” screw.
When the entire stem-band is screwed into place, use more bedding compound to fill any gaps. Then scrape away the excess compound and ensure that there is a smooth surface between the stem-band and the canvas. The top surface of the stem-band is then cleaned with a little lacquer thinner in a rag.
I like to show off the brass once the canoe is completed. Therefore, the day after the final coat of paint is applied, I use a utility knife to scrape the paint from the stem-bands. This will also remove any old paint or tarnish from the brass. If you attempt to clean the brass before it is installed on the canoe, you may break the stem-band (the voice of experience is talking here).
Use extra fine steel wool to polish the brass. Paint that is scuffed around the stem-bands can be touched up with a little extra paint and an artist’s brush.
Check out Kettle River Canoes.
Path of the Paddle (Part 1 of 4): Bill Mason Shows Off His Chestnut Pal
December 20, 2009
Bill Mason’s first canoe was a Chestnut Pal that he bought in 1958. The 16’ Pleasure canoe made by the Chestnut Canoe Company had just been changed from 34”-wide to 36”-wide and the name was changed from the Ajax to the Pal. By the time Bill made his “Path of the Paddle” series of instructional canoe skills films (1977), his old Pal showed the signs of a life well lived.
In the first film of the series, “Path of the Paddle: Solo Basic”, Bill introduces the public-at-large to the art of paddling a canoe. In 1977, it was a dying art and these films breathed new life into the world of canoes and canoeing. For those who know their canoes, Bill seems to take delight in showing the world what the Chestnut Pal can do on the water.
Bill doesn’t discuss the canoe specifically. However, there are many aspects of the canoe’s design that come to light as he demonstrates the basic skills. For example, the Chestnut Pal has a keel. Mind you, it is a shoe keel (2 ½” wide and 3/8” high) – designed more for protecting the bottom of the canoe than anything else. It certainly doesn’t hinder the canoe’s ability to maneuver in the water. Beginning at 13:19 minutes into the film, Bill demonstrates side-slipping – moving the canoe sideways in the water. He explains and demonstrates how this is used to avoid rocks in a river. He also shows how the Pal can move gracefully through Class 2 rapids. It is not designed to handle rapids much beyond Class 2 rapids, but that doesn’t stop Bill.
The canoe has fine entry lines and a fair amount of rocker at the ends. These combined with a shallow arch to the hull make for a very easy-paddling canoe. The Pal also has a pleasing amount of tumblehome amidships. This is the curve on the sides of the canoe as the inwales come in towards the centre of the canoe. When a solo paddler sits over to one side of the canoe and nestles into that curve, the canoe tilts over on its side. The waterline of the canoe then transforms the side of the canoe into the bottom. Since the Pal is 36” wide, as it leans over to the side, the ends of the canoe lift out of the water. This is seen clearly at 17:24 minutes into the film. In this position, the actual length of the canoe in the water is reduced to about 12 feet. As a result, the canoe turns very easily; a characteristic that is welcome in a wide variety of circumstances on lakes and rivers.
Almost every wood-canvas canoe that I can think of (except a V-stern canoe) is symmetrical in its design. That is, both ends of the canoe have the same shape. This allows paddling with equal efficiency regardless of which end is pointed forward. The symmetry offers a versatility that is shown to be a great advantage at 18:44 minutes in the film. When met with a strong head-wind, Bill simple reverses his position and paddles efficiently into the wind with the weight now placed in the bow (which was the stern a moment ago).
Actually, you’ll notice throughout the film, that the solo paddler sits on the bow seat facing the stern for most of the skills. This is not possible in many modern canoes equipped with bucket seats. There is a reason that “old-fashioned” canoes are designed the way they are. A canoe is built to be used on lakes and rapid rivers both solo and with a partner. Bucket seats are fine as long as the only paddling you do is in a straight line on flat water with two people paddling. To my mind, a canoe is truly a canoe when it can be used in a wide variety of conditions – both solo and tandem.
The only modification I make to the traditional design of the Chestnut Pal (and other wood-canvas canoes) is to remove the 4” bolts holding the seats and replace them with 6” bolts and correspondingly longer spacers. By hanging the seats 2” lower, the paddler has a much greater degree of stability (a centre of gravity below the top of the inwales). At 3:03 minute in the film, Bill demonstrates sitting on the seat with his legs extended. Note that he has to use a sculling brace to maintain stability. It is amazing how much more stable that position is when the seats are 2” lower. The seat is still high enough to allow the paddler to get his or her feet under the seat for regular paddling.
I love watching this film just to see the Chestnut Pal being taken through its paces. So, take a few minutes (27:53 minutes to be exact) and enjoy this classic instructional film. Merry Christmas to all.
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