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Recycled tempered gl ass captures solar energy to heat air, which is circulated by an attic exhaust fan .

The fan and


plywood end wall are removable, permitting end-loading, in this case of 16' -long boa rds stickered in a 4' stack. The kiln
is unloaded when the desired moisture content is reached-15% to 18% for boatbuilding wood. Precautions against
deterioration, such as the use of treated lumber throughout and stepped flashing beh ind the bottom edge of the glass
side panels, help to prolong the kiln's life. Pieces securing the bottom of the wall glass may trap moisture; simple blocks
of wood or UMHW pl astic would work well.

~
o l a r kiln is a cos t-e ffec t ive way to dr y g ree n hum idity. H arnessin g the free ene rgy of th e sun , th e solar
lu m b e r. Tod ay, m an y ban dsaw o pe ra t o rs cu t kiln o perat es on th e n atu ral cycle of warm days and cooler
lu m be r from tr e e s th at g row in ab u n d ance in n ig h ts to ge n tly d r y wood and prevent in terna l st resses
much of America , and a solar kiln can not only finish the that can r u in lu mber dried by ot her m ethods.
d r yin g cycle m ore qui ck ly th an air drying but also avoid T he kiln presented her e is sim ple to bui ld , an d its o n ly
d efects cause d by exp osUl'e to wea the r, m old , an d bugs, ope rat in g cos t is for e lec tr icity to run th e fan. T hese fac-
The kiln d ries lum ber by co ntro lling temper ature an d tors m ake th is kiln pract ical for the ge neral wo odwo rker,

90 WoodcnBoat 182
Far left-Metal brackets
secure the t o p glass panels,
which exp and and cont ract
-: I
with heating a nd cooling , t o
the rafters. Soffit-vent cov ers
at the front and back walls
can be removed or adjusted
when ventilation is needed.

Left-5imple masonry blocks


form a rudim enta ry found a-
tion. An important de t ail is
t he stepped flashing set
behind the w all glass panels .

and the structu re co u ld easily be length ened- an d per- of 6 % to 8 % with m inima l o pera to r m an agement.
ha ps a secon d fan ad de d at th e o p posite en d-to h andl e H o wever, for boatbu ild in g it is im portant to m on itor
th e lo ng boards a n d timb ers needed by the boat b ui ld er, m ois tu re co ntent to kee p it from going be low the desir-
a ble ra nge o f 15% to 18 %.
How It Works
Evaporatio n fro m th e su rface of wood occu rs when su r- Building the So lar Kiln
rou nd ing air absorbs the water, The capac ity of air to hold T he kiln shown here has a ca pacity of 1,000 to 1,500 bd
wat er is d ep e ndent o n te mperatllre , T hi s is exp ressed in ft of lumber, which is abou t o ne to n , or abo ut two to three
the te rm "relative hu m idi ty," where hu midity is the degr ee good-sized p ick up truck loads of ha rdw ood boards. T he
of saturati o n in a given volume of air, co m pa re d to th e ki ln is b ui lt wid e e no ugh to h ol d a 4 ' stac k a n d long
amo unt it ca n hold at any given tem p e ratu re , Wh en tem- eno ug h to fit th e longest lo gs we a re likely to have sawn ,
peratures fall, m oi stu re from saturated air precipitat es. wh ich is usually 16 ', You can adapt th e size to sui t specific
Wh en te mp er at u r es ri se , the a ir ca n hold in cr e ased cu tt in g needs, an d boatb uild ers would p rob abl y need a
a m o u nt s o f m oi sture , A tempe r ature in c re ase fro m longer kiln .
0
70 to 1200-which is th e ra nge in whi ch the so lar kiln The co nstructio n uses sta nda rd 2x4s, Y., " plywood sides,
works- in crease s the a irs m oi stu r e-h o ldi n g ca p ac ity a Y." plywood fla m', and 4x4s and ca p blocks o r sho rt pOSLs
tenfold. T he amb ien t ai r o n a hot , st icky day in summer for a foundat ion . T he so u th wall a nd ro of are mad e from
at 100% relati ve h u mi d ity, wh ich offers little ca p acity for recycled tempered glass of th e kind used in slid ing pati o
d r yin g , becomes desert-dry ai r o f 10% relati ve humid ity doors. Because th ese ther mopa ne uni ts have a nast)' habi t
0
when the su n heat s it to 120 in sid e the kiln . of develo p in g air leaks in the sea ls, whi ch fogs the g lass,
Another operati n g prin cip le is the da ily warming a nd used glass is readily availab le fro m co m pa nies that work
coo ling cycle, in whi ch th e sun 's ene rgy shu ts o ff at n ight. in th e replace ment b usiness. T he co n d it io n o f the sea l
T h is is key to the trouble-free o pera tio n of th e solar kiln , d o es no t affec t the kiln , beca use we use single-laye r glass.
T he da nger in herent in st a n d ard hot-air dryers is fiber We d o n ' t n e e d t h e n ightt im e in sul a tin g qu ali t ie s o f
stress ca use d by shrin kin g of th e wo od 's su r face be fo re d ouble-pane glass b eca use th e kiln sh u ts d own an )'way,
its core ca n d r y. Su ch stress no t o n ly warps lu mber b ut an d during the day the seco n d pane wo u ld block 10% of
also ca uses "case h ardening," whi ch is what we encounter the su n lig h t. To se pa ra te th e o ld th er m opan e s, run a
when o u r saw blades b ind when we ' re sawing a board. In util ity knife a ro un d th e edge be twe en th e glass an d th e
th e sola r kiln , board s h ave a chance to "normalize " eve rv seal. Don 't scra pe what re mains of th e rubber sea l off th e
d ay-what I like to th ink of as smoo thi ng o u t the d iffel:- glass; leavin g it th ere will make fo r a be tte r in sta llation .
ences in m oi stu re level s th roughout the wood. Beca us e Before p lan ni ng a str ucture , you must first obtain the
of th is d aily cycle , wood int ended for so me furn itu re an d recycled tem pered g lass. T he size of th e panes will det er-
ca bin joi ne r y will en d at th eir desired m o isture co ntent m in e th e spaci ng of studs and rafters as well as th e exact

J anua ry/February 200:; 91


overa ll size o f the bu ildi ng. The standard th ermopan e in (the pi eces th at sepa ra te the b oa rd s in th e stac k), but
an S '-wide patio door is 46 " x 76 " an d in a 6 '-wid e patio d on 't u se wet wo od h ere -it ca n ca use m o ld g row t h
d oo r 34" x 76 ". Eith er size will work; it is th e 76 " lengt h known as sticker sta in. Take the time to make st ickers o f
that will span the width o f the roof. The edges of the glass dry wood , an d prot ect them from rain when they're not
ne ed to b e su p p o rte d o n 2 x4 framin g , wh ich will b e in use . Ours are 1.1" thi ck by I " wid e rather th an the full
adjusted acc ord ing to th e size of th e g lass. I " sq ua res that co m me rc ial o pe ra to rs use. When stac k-
I h ave learned from dism antl ing older kilns th at using ing, space the sticker s about 3 ' ap art and in line o ne ab ove
pressure-treated wood will add years to a building's life . the other to avoid bending th e unsupported lower boards
Rafte rs , sills, he aders, flo o r pl ywood, and foundati on with all th e dead we ight of the load above . You will need
framing all need to be rot-resist ant. ab out 200 sticker s when fillin g a kiln the size of o urs.
Don 't be co ncerne d with sto p p ing u p all th e crac ks Also , when stac king lu m b e r, space the bo ards a few
and sea ling the d oors. T his bu ildi ng works well with th e inches apa rt side-to-side to in crease airflow. We have expe r-
level of co n str uc tio n used for a hen house . Some air flow imented wi th various ways o f m ovin g air, and we 've found
wou ld b e in order. To produce defe ct-fr e e lumber- that it works best to sim p ly have a large-vol ume fan at o ne
esp ec ially fre e from case-h arde n ing-vent the kiln as lit- en d flowin g th rough th e stac k with the boards spaced I "
tle as possible, usually o nly if the temperature gets ab ove to 2 " apart . However. we ofte n leave an additional "ch im-
0
ab ou t 140 The key is to move moisture out of th e wood
• ney" 6 " wide up the middle of th e stack closest to the fan.
by heat but no t cre ate a dry su rface, hen ce to keep th e If yo u' re drying to a low moisture co nte nt, th en once
air warm bu t moist. Mo istu re will co n de nse o n th e kiln 's th e wood is dry, restack it with out stickers. T he reason for
walls at night, so a floo r drain migh t be inst alled. this is th at wood can ea sily reabs orb moi sture durin g po or
T h e foot le dge on whi ch th e sou th wall's g lass rests drying months. However, th is is not a prob lem if you are
must be fitt ed with flashin g. bent to h ave a YJ " step so it only drying to the ambi ent o uts ide rel ative humidity.
ex te n ds be h ind th e glass, over th e top of th e ledge , and Everyone asks how lon g it takes to dry lu mber in a solar
down the front. The ro o f glass ne eds special attent io n , kiln. Ther e are many answers, ran ging from four week s
too. U n like wood , glass ex p ands an d con trac ts with tem- to six months, dep ending on the species of wood , its thi ck-
p erat ure cha nges. and this resu lts in a tenden cy of th e ness, th e sea so n, an d th e fin al m oistu re co nte nt desired.
roof glass to creep down the slo pe . To co u n te r thi s, a Wood u sed in furni ture makin g is ge ne ra lly d ried to 7%
bracke t mad e from a d ouble fold of flashing I Y.!" x 14 " is mo isture co nte nt, but for most b oatbui ldin g purpo ses,
screwed into the rafter near th e eave en d . If th ese scre ws 15% to IS% is typical. Air dr ying l 'e thick hardwood wou ld
were set in the facing board o n ly an d not th e raft er, th e typi cally ta ke a yea r, wh ile so lar dr ying bo at lu mber will
glass ex pa n sio n cou ld push the fascia board a u t. take a month or six week s in summer.
The kiln works when warm air is circ ula te d through Two other factors affec ting dr)~ n g times are the species
th e sta ck o f bo ards. Wit h good air circ u la tio n , no vent- of wood an d its th ickness. Softwoods like pine will dry in
ing sho u ld be need ed un less exceed ingly ho t co n d ition s half the time of h ardwoods like oak o r maple . As thi ck-
prevai l. T he adjustable so ffi ts alo ng th e ea ves provide ness increases, so does the length of time , in proportion:
ventilat io n when ne ed ed . A high-v olume fan circ u la tes twice the thi ckness, twice the time .
the air ; a 30 " att ic fan can do the j ob . The fan mounts o n Because of its ni g ht shutdown charac te r istic, a so lar
a removable 2x4 frame near the end o f the kiln th at opens kiln takes longer th a n other typ es of kiln s to d ry wood.
for load ing . T he frame fits into hol d in g slo ts so it ca n be The seaso n , predictably, is also a major factor. I-Iere in
lifted out during lo ading or for servicin g. T h e power is Michig an , kiln s wo rk effect ive ly from March through
co ntrolle d thro ugh a the r mal switc h o f the sort u sed in O ctober. During winter, wood can be dri ed down to about
farm silos . This will be se t for seaso nal n ighttime tem- 12 % to 15% moisture co n te n t- be lo w a boat bui lde rs
0
p erature , wh ich in Mich igan is 700 in su mmer and 50 in needs-but it takes wa rmer weather to reach th e lower
sp ring a n d fall . mo isture co ntent th at a furn iture maker wou ld prefe r.
Becau se of all these variables, you need to have a mois-
Op erating the Kiln ture met er to tak e the guesswo rk out of de ciding when
Lu mber h as to be st acked in th e kiln by hand. For access to u nl o ad . Also , chec k th e moisture content p eri odically
th e thre e 01' four times a yea r th at we load th e kiln , we wh ile unload in g , b ecause th e top layers dry sooner th an
rem ove the en d p an el an d one sec tio n o f plywoo d in th e lower o nes do . The qu ality of sun-exposed boards is likely
back , where a man st ands to ad d st ickers durin g stac k- to be poor, so some kind of screeni ng th at keeps d irect
in g. Having the back open also makes it bearable to wo rk su n ligh t o ff the boards is de sirabl e .
in there on a sunny day. After loading , th e large en d p anel The ben efits of a so lar kiln for a small shop operato r
is scre wed into place, with a 16 "-wide secti on hinged to are ou tsta n d in g. It provides th e means for co n vert ing
affo rd easy acc ess to chec k th e kiln as drying progresses. readi ly available gree n lu mb er int o fini shed stoc k. Low
It h as proved co nve n ie nt to re move th e en d panel for co ns tr uc tion a nd operatin g co sts make it po ssible to eas-
access, but the pan el is str uc tu ra lly necessary to keep the ily b egin wit h a sin gle kiln a n d add another if needed.
building fro m sag ging, so it needs to be scre wed in place Co u p le th ese eco no mics with a se lf-regu la t ing dryin g
excep t when load in g an d unloading. cycle, an d you h ave a u ser-fr iendly system for the sm all
The kiln co uld be loaded from the rear by a forklift, but bo atshop . ..A..
its str uctu re wou ld have to be strengthen ed with a co up le [olin IFil5011 is a WOOdWOIilel; boatbuildei; and teacher living ill Charlotte,
o f 2 x 12s ac ro ss the top of the back wa ll to allow for th e Michigan. He also has a business sUI/jJlying materials to Shaker oval
sim ulta neous removal of all the back plywood panels. box makers. He built his first solar dl)'ing kiln in 1984 and currentls
Scrap s cu t whi le mi lling can b e a so u rce o f stickers has fi ve.

92 Wo o r!CIlBO<1l 182
WOOD TECHNOLOGY ~

Boat Planking-
Too Wet or Too Dry?
by Rich ard Jagels
Me (%) = weig h t of wood co nt ain ing
A ll wood co ntains va rying amounts
of water. So me of thi s is in liquid
o r vapm' for m in ce ll ca vit ie s
water - 0 0 weigh t / OD weight x lOa,
th e substance tha t co m poses ce ll walls
of wo od is heavi er th a n wat er (sp e-
cific g ra vity 1.5 versus 1.0 for water) ,
(lumen s) ; this typ e is d ispl aced an d Green Woo d woo d ca n h ave a m o isture co n te n t
is known as "free water." Wat er in cell "Gree n wood " is a term that describes be low Mm ax a nd still sin k in water.
wall s, o n th e o t he r h and , is wea kly wo o d th at h as wa ter-sa turate d ce ll Various woods h ave varyin g abi li-
held by che m ica l bonds to ce llu lose ; wa lls an d also co nta ins free water in ties for a bsorbi ng m oi sture wh en in
termed "b o u n d wa te r," th is typ e is th e ce ll lu me n s. If bot h th e ce ll wall s d ir ect wa te r co n tact. Ad iro n d ack
m ore d iffi cu lt th an fr e e wa te r to a n d lu m e n s a r e co m p lete ly fill ed g u id eboat builders often a rg ue d the
rem ove. If wo od is d r ied in an oven with water, g reen woo d h as reached m e ri ts of pl ankin g th ei r boats with
at a bo u t 215°F (102 °C) , a te mpera- m aximum m oisture co ntent (Mmax) . n ati ve ce dar o r pine, T he advantages
ture j u st b arel y a b ove the bo ili n g T hi s m aximu m is rare ly a ttained in o f cedar were revealed in the newly
p o int of water, all Iree wat er an d just th e living tr ee , altho ug h the sa pwood co n structed boat, wh ich weighed less
ab o u t a ll bo un d water will b e o f so me tall co n ifers suc h as redw ood than a boat p lanked with pine . At a
remove d . T h e we igh t of oven-d r ie d and "Vestern red ceda r m ay co me ver y n omin al m oi sture co n te n t o f 16 % ,
( 0 0) wo o d b ecomes th e r eferen ce cl o se , Mm ax can range fro m 267% ce dar we igh s abo u t 21 Ibs per cu b ic
p o int fo r d et erm ining the m oi st u re for a wood th at has a specific g ra vity foo t, whi le pine is closer to 25 Ibs. No t
co nt e nt o f woo d that co nta in s vary- o f 0.30 to as little as 44% fo r a wood a h u ge differen ce , but weig h t was a
ing amou nts of free and bound water: with a spe cific gravi ty o f O.90. Because cr itica l facto r in a bo at th at had to be

-.. --
I :.l7i"fiT::Ji ilJ
-..
-
l'"H:I:lIR'I'IIll't"' L!,li1l'1'!llI •..,
Breaking strength
(modulus of rupture) Lower Higher

Stiffness
(modulus of elasticity) Lower Higher

Toughness
(rapidly applied load) Often higher Often lower

Tension perpendicular May be higher, lower, May be higher, lower,


to the grain or the same or the same

Surf ace hardness Lower Higher

Surface checking Generally absent Increasing with


decreasing MC
Weight Higher Lower

Decay resistance Low, but improving Higher


toward Mmax

Planking or decking seams Tight Looser

* For this table, green wood has an MC above FSP (usually 30%); dry wood has an MC generally below 20%.

January/ February 200.'i • 93


WOOD TEC HNO LOGY

ca rrie d on so me onc 's sho u lde rs over fibe r satu ra tio n po int. Wh at ex ac tly more sta b le plan king-o r deck ing.
lo n g po rt agcs betwe en lak es in th e is the fiber saturatio n point (FSP)? By To pu t some numbers to th e co nce p t,
Ad irondacks. de fin itio n , it is g recn wo od th at h as if th e moi sture co ntent of planking
As the seaso n p ro gressed , however, fully saturated cel l walls, bu t no water in a boat ra nges fro m 16% to 40%, a
p in e-p lanked b o a ts began to sho w in the ce ll lu me ns. Wo o d technol o- wood like teak would sh rin k an d swell
th eir su perio rity. T h e ce da r bo a ts g ists like th is co nce p tua l, a ltho ug h o n ly be twe en 16% a n d a bout 2 1%
a bso r be d m a rc wate r a n d after sev- somewhat a rt ific ia l, sta te becau se wh ile a wo od like oa k may shr in k and
e ra l week s becam e heavier than the wo od begins to sh rin k an d stre ngth swell between 16% an d 30%.
bo a ts pl an ke d with pine . To d ay, o f p ro perti es cha nge bel ow FSP wh ile
co urse, we ca n sea l strip-b ui lt boats st re ng th a n d dimension al cha nges Me and Strength
to exclu de wat er- b u t not wit ho ut rem ain un ch an ged ab ove it. Although Wo od technol o gists o fte n make th e
ad d ing so me wcight with the cpoxy- p recisely determin ing FSP is di fficult all-en co m passing sta te me nt that d r y
a nd-fi be rg lass sheath ing. (and wood rarely has a uniform mo is- wood is stro nge r th an green wood. In
So how m uch wat er is d esirable in tu re co n te nt t hro ug ho u t), we ca n ter ms of stiffness an d breaking
trad iti on al boat p la n king , especially detect whether we are above or below streng th under a static load , the sta te-
bel ow th e wat c rl in e ? T he a nswer FSP by how prop ert ies cha nge, or don' t men t is tr ue. But so me o the r streng th
depe nds o n th e typ e o f b o a t an d cha nge. In the ta ble, o nly weigh t and, properti es m ay be as high or high er
whet her it will be o n a mo orin g all to so me d eg re e , d ecay resis ta n ce in gree n wood. Tough ness-strengt h
seaso n or in and ou t of the water. T he cha nge above FSP, Decay resistan ce ofa bea m when a load is applied very
fo llowing d iscussion app lies mo st is low at FSP, but as water re places air, ra p id ly- is o fte n h ig h e r fo r g ree n
cogc nt ly to a ca u lke d -sea m b o at, less oxygen is available for fu nga l res- woo d . Similarly, altho ug h d r y wo od
bu t a lso has re levan ce fo r la pst ra ke pira ti on unti l fin a lly at Mm ax no may require a greater force to achieve
co ns tr uc tio n as well as for deckin g. gaseous oxygcn is availab le. fa ilure u nde r a sta t ic lo a d . m ore
At wh a t m o isture co n te nt is FSP wo rk (fo rce through d ista n ce ) may
Fiber Saturation Point reach ed ? T he ge ne ra l an swer is about be ex pe n de d br eak ing a co mparable
T he table lists some contrasting prop- 30%, But in some wood s, suc h as teak, g reen-wood beam . Wh at th ese da ta
ert ies for green a nd d r y wood . Man y FSP ca n be as low as 18%-22%. Sin ce sho w is that g reen wo od ben d s more
o f th e se p ro p ert ies beco me m o re d imensio n al an d stre ngt h p ro pert ies befo re b rea kin g , a bsorb in g co ns id-
d ivergent as the d iffe ren ces in mois- va ry wi th moi stu re co nte n t, wo o d s erable ene rgy in the process. For some
ture co ntent becom e greater below the th at h ave a lowe r FSP will p ro d u ce species, tou ghn ess of green wood can
WOO D T E C H N O LO G Y

be dram ati cally hi gh er than for dry bui ld er h as wh en choosing a p p ro - abso r ptio n to a co nside ra ble exte nt.
wood . Southern yellow pines arc goo d priate planking is how mu ch the To summarize an d co me ba ck to
examples. An avcragc of three species wood will shrink or swe ll with chang- the question of how much moisture
shows that to ug h ness of green wood ing m oisture co ntent. Wh atever th c is desirabl e in bo at pl ankin g, a sim-
is almos t twice as high as wood at 12% cho ice of wood, quarter-sawn boards pl e a nswe r is th at for a sma ll boat
moi sture co ntent. On the o the r hand, will be more dimensi on all y sta b le where wei ght is im po rta nt, usu all y
Dou glas-fir sho ws littl e di fferen ce in th an nat-sawn . But even quarter-sawn meaning a bo at th at is in and out of
to ug h ness re g ardl ess o f m oi sture woo d va r ies co ns ide ra bly betw e en th e water, a low moisture co ntent of,
co nte nt. spec ies . In ge ne l"al, a species that say, 12% to 16% is desirable, while for
The pmperty o f "tensio n pcrpcn - p rodu ces co p io us extrac tives in th c a bo at tha t is larger an d stays in th e
di cular to th e g ra in" is o f inter est for hea rt wood will be more dimension- wate r for the season, a h igher m o is-
planking th at is fastened in such a way ally sta ble, assu m ing th at o n ly heart- turc co nte nt (20% to 30%) is gc nc r-
th at sh rin kage or movem ent aga inst wo od , and no sa p wood , is c ho se n . ally appro priate. Above 30% moisture
fram ing can induce stresses across the The reason for th is is that the extr ac- co nte nt, few advantages accrue. The
grain. Green wood may be more resis- tives fill so me of the voi ds in th e ce ll o n ly excep tio n is in creased d e cay
tant to splitt ing under these stresses, wall that mi g ht otherwise be occ u- resistan ce , but th e sacrifice in terms
althou gh in som e cases no d ifferen ces pi ed by wat er. T h erefore , th ese of in creased weight is likely not very
ar e seen an d in other cases dry wood wo ods re ach fiber satu rat ion at a acceptab le. For example, ' ''estern red
is stronger, Amo ng th re e species of lower moisture co ntent. And as p re- ce d a r a t Mm ax wo uld have a mois-
wh ite oak, for exa m ple, stre ng th in vio usly no ted , th is pro du ces more tu re co ntent of more tha n 250 %-
ten sion per pend icu lar to the grain is stable wo od u nder varying mo isture qu ite a lo t of ex tra water to h a u l
hi g her in g ree n woo d of b u r oak co ndit io ns. a ro u nd . Rcga rd less o f boat size , a
( Q uercu s macroca rpui , lower in gre en U nfortu n a te ly, the p rescn ce of woo d wit h h igh ex trac t ive co nte nt
wood of overcup oak ( Q uercus lyrata) , he ar two od ex trac tives d o es not sho uld bo th ret ard decay an d mi n i-
and essent ially the same fOI"green and precl ude a woo d from abso r bing mize move me nt wit h mo istu re con-
d ry wood at 12% moisture co nte nt of large qu an ti ties of water above FSP, tent cha nges. ~
po st oak ( Q uercus stella ta ) . Go figur e ! as in the ca se of ce d a r, and , th ere- IJl: Richa rd J agels is a professor offo rest
fo re , ad d ing co n sid e ra ble wei ght. biot ogy at the University of Mai ne, Oron o.
Shrinking and Swelling Effe ctive se al ers, including tun g Please send correspondence to D,;Ja geL, to the
One o f th e bi gg est co n cern s a bo at- o r linse e d oi l, ca n reduce wat er care of Wooden Boat.

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