Resolution to the Errors We're Experiencing

We received an answer that thoroughly answers the questions regarding the fit problems we've encountered while assembling the hull. The short answer is that it's a combination of problems with how the kit was cut at the factory, and assembly error. If you're interested in the long version, I'm attaching the response from Jacques, one of the admins at www.bateau.com

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Here are Ryan's conclusion[s] and I agree with them. We have looked many times at this and suspected a problem if parts were cut from the nesting drawing. We found only discrepancy . Ryan's notes are in italic. My comments are in blue.
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"The aft pieces of the hull bottom were too wide where they meet the middle pieces of the hull bottom. I laid out the plan spec dimensions on these pieces and had to cut off slivers approximately 5/8" wide, tapering down to 0", by 20" long, in order for these pieces to meet the plan specs and to get them to butt properly to the middle bottom hull sections. The cuts were on the outside of the pieces."
---->I have no clue about this. The nesting matches the dimensions.
That must have been a CNC machine problem. Fortunately, it was too large and easy to correct.


2) The aft and bow transoms were mounted on the building frame, at the distances and angles specified in the plans. A laser was used to precisely align everything. When the glued and assembled stringers were put in place, it was clear that they were about 3 inches shorter than the distance between the transoms. Part of this distance (1/2") can be explained by the fact that I did not account for the front cabin bulkhead fitting between the aft and bow portions of the stringers, as I had glued them up as one contiguous unit (instead of installing the bow portion of the stringers later, as indicated in the on-line building tutorial). However, having to recess the stringers 1/2 way into the transoms adds 9/16" for the bow transom and 1" for the aft transom (which is 2" thick for large motor usage). This adds up to: 3" - 1/2" + 9/16" + 1" = approximately 4 inches that the stringers were short. I do not recall what the exact measurements are, and I did not try and crawl under the boat to take them again. Thus, I cannot say whether this is a plan or kit error."
---->the kit: The transom that was in the nesting was too big. It was about 1-7/8" too big. The stringer tips in the nesting were about 1" too short.

The CNC file for those parts was taken from the nesting drawing but the nesting drawing is not to scale!
You corrected properly.


"This problem was corrected by moving the bow transom aft the proper distance so that the stringers would fit right. I knew this could change the way the bottom panels fit, so when we put the aft 3 building molds in, we reduced the distance between each of them a small amount. This was done because the bottom is much flatter in this area and I knew it would affect the shape/fit of the panels less than adjusting each mold position or just the front ones."
--->Once they do this.....the frames won't fit right.
That looks like an assembly mistake you made but again, you corrected it properly.

"Some of the kit frames were not wide enough. For example: According to the plans, Frame F should be 90-1/4" wide. The actual measurement is 88-1/4". Frame E should be 92-3/4", and the actual measurement is 90-3/4"."
---->The nesting matched the station dimensions....so I don't know about this.
Me neither . . . were those frames marked correctly?

"Several of the kit pieces that were supposed to be 3/8" plywood were actually 1/2". I have been able to work around this without too much problem and the small amount of extra weight should not affect the performance."
---->Not sure about this one either.
I discussed this with Eric. he asked permission to use 1/2" instead of 3/8 for cutting reasons. I checked and gave the OK, it has no effect on weigth (maybe 5 lbs total!) and can only be better question of strength.
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Conclusion, it looks like there were some problems with the kit, some I understand, others not but you solved the problems. Sorry for those cutting mistakes. Email when you need paint or other supplies, we'll do something special.

All the dimensions on the plans are correct, it's a kit problem that does not affect those building from the plans. Eric and I have discussed this. In 95% of the cases, despite what we say on the plans (NTS = Not To Scale), our plans are to scale. Those parts were an exception. Right now, we do not cut kits from the nesting drawing anymore.
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Jacques Mertens

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My personal opinion on the whole deal...

The root of the problems were based on errors in the kit. The problem was exacerbated when we adjusted our assembly process upon encountering kit errors, resulting in a chain reaction of minor, correctable issues.

Jacques and crew have been instrumental in figuring out the root of the problem, and there's no doubt in my mind that they'll work with the kit manufacturer to ensure this doesn't happen again. Additionally, they appear to genuinely care about customer satisfaction, as evidenced by their promise to "do something special" next time we order supplies. Despite the fact that we've experienced these minor setbacks, I have been satisfied in my dealings with these guys, and I would freely recommend bateau for anyone who is building a houseboat (or any other type of boat.) "If you're building a houseboat, go to www.bateau.com for the plans, kit and supplies."

By the way, if you do end up ordering from bateau as a result of reading this blog, tell 'em that OzzyC sent you.