clamps now are just to hold the ply in rough position and will be loosened to allow movement as
the straps are tightened.
Place three strap clamps (cargo ratchet tie downs) around the ply starting at the top. Hook the
ends together to make a loop, with the hooks and ratchet in the space where the bottom will go
and snug it down - just snug, don't crank, yet. Place the top strap and snug, then one in the
middle. Check inside to see that the ply is pulled up tight to the form all around as you tighten the
clamps. You'll have to place the clamps that hold the end to the braces leaving space for the
straps. Crank the straps and recheck the fit inside. When you're satisfied, remove everything,
place within easy reach, run a bead of glue around the kerfing, both sides. Too much and it will
start to drip all over everything. You want enough for a good joint but not an excess. You can't do
this gradually, a foot at a time like the kerfing because you're doing both sides at once. Be quick!
Get the kerfing glue applied, then run glue along the rear brace - be more liberal here, as it will be
under more pressure. Slap the ply on, clamp the end with a few to three clamps and get to
bending around while that glue is displaying its obedience to the law of gravity. Glue up the other
brace, throw on a clamp or two to hold it temporarily, get those straps in place! Don't get right
next to the edge of the ply or you'll glue the straps in place too - allow ! inch or so from the inside
edge. Snug the straps - you'll have to release the clamps on the front once the straps start
holding the ply to allow it to move as you crank the ratchets down (don't test the breaking strength
of everything, but crank it down and check inside to see that the ply is seated to the kerfing all the
way around, especially along the flatter top section). Now go back and add C clamps to those
ends, at the outermost edge of the braces, where the pressure will be greatest. Check to see that
the ply is seated completely at both ends. Now relax, breathe, the excitement is over - until the
next layer of ply. Let this set up overnight.
In the morning, remove the straps and clamps, clean the joint between the side and top with a
scraper. You can trim the ply overhanging at the braces with a mat knife, making repeated light to
medium cuts against the brace as a guide until you cut through. You may want to support the
edge as you do this so you don't pull the ply loose at the edge as you cut with the mat knife, just
don't support it with a slashable body part like a finger. Clean the face of the braces with the
scraper. Test fit the second layer of ply to see that it'll go around without binding. If it does bind,
check for glue on the inside of the side you may have missed. As a last resort, sand the edge of
the ply where it's sticking. Clamp the rear end in place, bend around to the front and mark the
length, allowing some extra to trim later. It will be a bit longer than the first, because of geometry
involving circles and pies. Remove and trim the front end to the newly marked line.
Apply liberal amounts of glue all over the first layer of ply. I used a small medium nap paint roller
and pan of glue to apply a lot quickly, then went over it with a serrated putty knife to be sure it
was spread evenly. You have to be quick! Do this later in the morning, after you've had your
coffee. As soon as the glue is spread, apply the second layer of bending ply, again starting at the
rear, lots of clamps to hold in place, allowing space for the straps top, middle and bottom, straps
slightly away from the edge (deja vu yet?) Snug the straps lightly, massage the ply, back to front,
to make sure it's seating all around, especially the flatter sections, as the straps can't apply as
much pressure there - the straps can actually apply lots of pressure where the bends are tightest
in rear and front and prevent the flatter section on top from sliding around forward to seat fully if
you just crank the straps tight. Crank the straps down, check the outside edge to see if there's an
equal reveal all around indicating the ply is seated. Wipe the glue joint on each side with your
finger or a small putty knife to clean up some now and have less scraping later. Breathe, relax.
Let everything set up overnight. In the morning, remove all clamps and straps. Clean up the joint
between top and sides with the scraper. Now is the time to prime the interior – almost.