I guess it has been a while since I have posted.  Some progress to report.  I managed to finish a wooden steam box - used the same design as the styrofoam try 4.  Works fine!  Temp gets up to about 205 - not quite as hot as the styrofoam box, but can be used more than once!

Last week I steamed removed, cleaned, steamed and installed 2 more ribs, these toward the center.  Then this week, did the same again, this time replacing 2 more toward the stern.  So, up to 5 ribs installed!  So far they seem to going in quite well, better than I expected.  All the prep, shaping of the ribs, etc. takes about 8 hours for 2 ribs, so that is about all I can do in a week.  None the less, at least I can see steady progress.

It was looking like the bottom was sagging a bit in the stern where the most damaged ribs are located.  I added another temporary 2X4 'keel', attaching it ahead and behind the damaged area.  This seems to pull the bottom up to flush and hopefully will keep the ribs in place until I get to replacing the bottom planking.

I think I am up to about 14 ribs that will need to be replaced - perhaps more.  I'll continue replacing them 2 at a time - looks like I'll need to shape a few more from the lumber we bought last winter.

First rib installed!  It is possible.

The rib sprung back quite a bit when unclamped from the outside of the canoe.  That makes it hard to get it worked under the gunnels (after turning the canoe right side up).  To remedy single handed, I put a strap clamp around the rib to pull it to about the right width.  This let me get it between the inner gunnel and the planking, but it still did not like to lie flush with the planking - the ends needed quite a bit of pressure down to seat.

(the following is the wrong way, I'll get to the right way in a moment...)  So, I put a single nail in one side of the rib while pushing down to get it 'close' to the right location.  Then on the other side, I pushed down quite hard on the end while pushing the inside of the rib out to the planking, to align the center mark with the keel holes.  Then again, a single nail to hold the rib to the gunnel.  All the while being careful to keep the rib aligned and centered between the remaining ribs.  At this point the rib was close, but not seated against the planking.  I then started nailing the planking to the rib working my way down from the gunnel.  I used the original nail holes in the planking to place the nails.  This pulled the rib in flush with the planking quite nicely, down to the bottom of the canoe.   I did not yet nail the rib to the bottom planking as much of it is rotten and will need to be replaced.  I then moved to the other side and tried to do similar, mostly failing miserably, until I realized the right way to do it...

So, the right way to do this is to use a clamp from the gunnel to the top of the rib, and use it to push the rib down and seat it against the planking. This worked like a charm, and allowed me to nail the other side of the planking, again down to the rotted section of planking at the bottom.

Result - one rib installed!  yahoo.  Of course, it is April only 6 months since picking it up!  And this is only the 2nd step.  Now another 12+ ribs to go, then fix the stems, then repair the planking, and then figure out how to canvas and then paint.  In other words, no end in sight...

Also, I have a wooden - try 5 - steam box almost complete.  Only missing hinges and clamps for the ends.

So, at last, it looks like some progress.  Next step is to remove another rib in the center section.  Should not be a problem to steam at least 2 at a time.

Well fans - after a few last minute re-considerations, there is indeed now a rib bent over the outside of the hull over the 4th rib from the bow stem (to be used to replace the 5th rib from the stem in the stern).

The adjustments - I re-read the Stelmok and Thurlow sections on replacing ribs and figured I needed a bit more prep.  Mainly, it looked like I would need quite a bit of pressure to bend the rib, and perhaps I needed something to hold the rib in place.  I did not like the brace to the ceiling suggestion, and realized there are holes through every other rib for the keel.  So, I found some small diameter bolts, cut some oak 'washers' and an oak 'keel'.  This lets me clamp the center of the rib in place when it is hot so I can bend the rib without worrying about it moving around.  (it worked like a charm!)

While I was reading I also noticed how they put some battens on the inside to pull  the hull into shape.  I tried some thing similar for the forward rib I am planning to work next.  I'm not sure it really pulls the hull in much, but will  report more on that later.

With that done, I figured I was ready to give the steam box a try.  I decided to stick a towel in the end to heat up with the rib so i could wrap the rib and keep it warm once it was well steamed (that seems to work also, but I'm not sure it is needed).  The steam generator, and Styrofoam steam box worked fine.  It took about 25 minutes for the generator to get boiling well.  The duct tape had a tendency pucker and soften, and there was some steam leakage, but the candy thermometer said about 205 degrees, and the meat thermometer well over 195 (its highest reading).  While waiting for the box to get to temperature, I 'soaked' the rib, keeping it wet with a rag.

I opened the end, pulled out the towel, put in the rib and towel back in.  I steamed the rib about 20 minutes (only putting it in once the box was up to temperature).  Took a bunch of pictures of the whole setup while waiting.  Pulled it out, wrapping it in the steamed towel, clamped it under the pseudo keel, put the warm towel over it, bent one side (working it up and down about a half dozen times) and clamped it.  Then went to the other side and bent it down the same way.

Amazing - no splits, or cracks.  The rib was hard to bend, but not terribly.  Holding it and clamping it was a bit tricky, but doable.  One lesson - make sure there are no nail heads protruding where you are trying to bend the rib.

Now letting it dry, and will see how it fits and nails into place tomorrow.

I'll note here that try4 at steaming while successful ended up being a one time use steam box.  The tape got a bit puckery and wet, but the box, while operating appeared as if all was well.  Then, after running in to bend the rib, I went out to clean up, and found the box in this state.

Apparently, the styrofoam was over-temped - and pretty grossly deformed on cooling.

Before dinner, I ran out and bought another $20 of lumber to build the box out of wood, maybe tomorrow.  Also need to shape the next rib.  There is one already removed, this one near the center so a bit longer...

OK OldTownRestoration blog fans, no giggling.  Tomorrow I try attempt 4 at steaming.  What does that attempt look like you ask?  Well, first I'll go back to try 3...

The 3rd incarnation was to be an enhance boiling water towel wrap.  I got it all ready, cut attempt 1 PVC in half, embedded the halves with a towel in between to insulate the  bottom, and use the old camp stove to hopefully keep the water boiling while continuously dipping in and pourning over the towel.  The problem arose when I went to start the old Coleman stove - I could not get any pressure in the gas tank :-(  After much frustration, I gave up and decided that I would likely not get hot enough anyway.  Back to the internet...

Where, I found that there are actually steam generators out there, that are likely less expensive than the parts I would need to build a propane bomb, er boiler myself.  Seems like a bit of a wimp out, but I made the purchase And $90 later I have a steam generator.

That leaves a steam box.  The manly thing to do, naturally, would be to weld up a nice, insulated, stainless steal torpedo, to go with the propane bomb.  Or for those woodworking purists, at least a nice wooden box with screws and tight seals.  But me, no,no,no - try 4 is made of styrofoam and duct tape!  I figure the styrofoam will insulate well, and I am using one wood board to build it around for stiffness.  No laughing until it all falls apart when the duct tape gets a bit soggy.  Until then, a few dowels for shelving and it seems pretty sturdy.  Tomorrow I poke a meat thermometer through, hook up the steam generator, and we'll see how hot it gets.