I bought the plan from Laughing Loon, you get a 1:1 template for all stations and a book on how to build it. It has many tricks.
The first step is to transfer the template onto a plywood. My daughter was quite excited when I told her I was building a canoe, she was doodling boats.
then I cut them out with a jig saw or bandsaw, two at a time, then sand it to line.
To align everything, I'm building a strong back with CDX ply for the sides, OSB for the top, and brace it on the bottom. It was put on my homemade sawhorse. You can see later it come quite handy that the top support piece can be swapped out.
http://www.noahsmarine.com/ it's actually cheaper to buy the milled strips than buy lumber locally and mill myself. To lower the shipping coats, I use 8' long strips. I bought around 1200 linear feet, they arrive ordered by color, I do find some strips the cove and beads are not centered, for those I ended up did quite a bit sanding after the stripping is done.
The twist is so bad, that I can't use a full length strip to close up the stern and bow. So I seal the stern first with a very short strip, then fit in the rest. It looks awful at the time, but after the magic of power sanding, it actually look pretty good.
I scraped and sanded the inside. It's harder than the outside, I use ROS for the flat places, and hand send the rest. I have to have a lot 6 inch sand disk for a 5 inch ROS, but that's actually works very good for curves.
Then I ordered some quality fiber glass, and System Three Clear coat epoxy. While waiting for those, I cut lumber for gunnels and paddles. The gunnel is make from walnut and poplar, that have a nice contrast. The paddle shaft is made from walnut and poplar as well, the blade is made from same cedar as the boat. I also sand the epoxy on the outside of the boat, man, those epoxy are hard.
Finally after a week of waiting, The low viscosity epoxy and a high quality 6oz fibre glass (from clcboats.com) finally arrived. The fibre glass was rolled not folded. It's very important, it's glass after all, folding will break the fibre. I roll the fibre glass on to the boat one more time, align one side of the cloth with one side of the boat, and trim the excess on the other side, this way the trim-off is big enough to cover those two panels for air tank and deck.
The new resin felt much thinner. I heated up the shop and mixed up around 150g to wet out one panel as a test, This time I use the pump, because last time during wet out, it gets very messy to mix a new batch with the pourring and weighting. The new resin wet out the glass almost instantly, with the help of a squeegee, I bring the puddle of resin to every corner of the glass, let it soak for 2 mins, then gently squeegee out as much as I can.
I mix 4 pumps of resin and 2 pumps of hardener at a time, the pump is pretty consistent, it's about 30g per pump. And only use squeegee to spread the resin, each mix cover about 4-5 sqf. I wet out one patch then move on to the next, after next patch is done, I go back to the previous one to squeegee out the excessive resin. On the bow and stern, where the surface is almost vertical, I use a foam brush to help spread the resin.
This time the wet out is very successful. the cloth is totally invisible, I think the key point is to keep the resin thin, either by heat up the shop or buy special resin.
It took me about 2 hours to do the glassing on the hull and two panels.
After around 24 hours, I flipped the boat over to give the inside a seal coat, then it's time to glassing the inside.
homemade jointer on one side, then planed it to about 1/2 inch thick.
Here I'm glueing up the handle for the paddles, and shape them.
After sanding the paddle, I put one the first sealer coat and then glassing it. I but a epoxy soaked nylon strip around the edge of the paddle blade, to protect the delicate blade edge, the cedar edge is pretty soft. I have to say the paddle turned out great!
Test run in Shoreline Park, the boat feels very nimble, a little wobbly then I wanted. I guess because the boat is so light. That's my wife and me in the boat.
The boat sitting in my garage looks great, but I still need to figure out a place to store it.
I hang the boat from the ceiling of the garage.