Boat building - first Tewantin taking shape

Boat building in plywood

In Brazil, the first boat built from the Tewantin plans is starting to take shape. The builder, Marco, has just completed his first project—a Noosa—which was featured in another post. That boat marked his entry into boatbuilding, and now he’s already deep into his second.

It’s great to see how quickly he’s taken to the craft. From first-time builder to confidently tackling a new design, Marco’s enthusiasm is clear. The transition from building the Noosa to now working on the Tewantin suggests he’s not only gaining skill but also enjoying the process. It’s always exciting to see someone dive headfirst into a new passion and stick with it. Well done, Marco—you’ve definitely caught the boatbuilding bug!

Manual finger jointing

Here are some photos Marco kindly let me share of the build so far. The frames are 9mm plywood, and the hull plating is 6mm. This time, Marco scarfed the plywood differently than before.

Typically, you’d join the sheets first, then mark and cut the parts from a full-sized panel. Instead, he cut the parts first, leaving extra length to make a toothed scarf—much like CNC methods, such as Andre’s “Noosa” build in Australia.

It’s a clever approach, clearly shown in this photo. The fit doesn’t need to be perfect either—epoxy with filler handles gaps well without compromising strength. The ply also bends nicely, judging by the photos of the bow. It’s a method I hadn’t considered before.

Stitch and glue method

As with his first boat, Marco is using the stitch-and-glue method to hold the plywood parts in place before bonding them permanently. He’s assembling the boat right way up again, which makes it easier to align and adjust the components as he goes.

In the latest photo, the hull is coming together nicely, viewed from the stern looking forward. The forward frame and under-seat frames are wired in place, clearly defining the shape. Still to be added are the three bonnet plates and the forward seat. More framing will also go in—along the tops of the sides, under the seats, and around the bonnet area—for added strength and support.

The engine mount is another key piece yet to be completed, but once it’s in, the overall structure will be nearly there. It’s great to see the Tewantin taking shape so well—Marco’s build is really coming along.

Thanks for the photos and feedback, Marco—much appreciated. It’s always a pleasure to see someone’s build taking shape and to hear how things are going. Even better when everything lines up just like it does on the computer!

– Tim

If you’re interested in building boats, download the free Building Guide. It’s a companion to my first book, Small Boat Building, which covers the construction of small plywood boats. The epoxy techniques included are just as useful for larger projects too. And good news—my second book, all about building Tokyo Express, is nearly ready!

Download the free Boat Building Guide for more tips.