Sam Devlin has been using the “stitch-and-glue” method to build wooden boats at Devlin Designing Boat Builders in Olympia, Washington, for over four decades. He’s built over 400 wooden boats from 8- to 48-feet long, and he also sells plans with instructions to those who want to build their own boat or hire a yard to handle the job. The stitch-and-glue technique relies on wire sutures to hold panels together until they can be joined by epoxy and fiberglass tape. Then, the hull is coated with fiberglass or Dynel cloth sheathing to ensure seamlessness. To make the process easier for laymen to understand, Devlin recently published the second edition of Devlin’s Boatbuilding Manual. Here, he shares details about the new book.
What motivated you to release this latest book?
Twenty-five years ago, when I wrote my first book on the stitch-and-glue method, I was introducing that building method to the world. Now it’s time to refine the introduction and what the method can do, which is allow virtually any builder to tackle a boat-building project, either small or large, and do it successfully.
How does this book differ from your previous titles?
It drills down deeper into the stitch-and-glue method and tries to explain some of the potential pitfalls the builder might encounter. There is much more detail from previous versions.
Is there a section you particularly enjoyed putting together?
Writing a technical book is a long process, but now that it’s in the rear-view mirror I’m happy to have the information out there. And I’m looking into new ways to disseminate the knowledge I’ve accumulated. Every day, I find a mind-and body-stretching glimpse into the world of creating things with one’s hands.
Are any of your recent projects highlighted in this book?
I tried to keep most of the references to projects that have been built in the last five to eight years at my company.
Can you tell us more about your professional background?
I’ve been designing and building wood/epoxy boats for 46 years and while in the business I’ve spent considerable time on the water with my projects. I have a 100-ton Master Captain’s license and now also have a small harbor tug business. This job has allowed me to work with amazing people who have trusted my company to produce products that are fairly priced for a good value. We have built 427 boats with the stitch-and-glue method and I have sold plans to more than 110 countries.
Which design is your most popular?
Of the semi-large boats the Surf Scoter 22 was the most popular small pilothouse boat.
What type of boat do you want to build in the future?
The Oysta 42 motorsailer.
What boat do you run and where do you like to cruise?
I’m starting a new chapter in my life with an upcoming long cruise trip to Alaska and back this coming summer season. I will be on my Puffin, a 47-foot trawler-type with a Gardner diesel engine.
This article was originally published in the February 2024 issue.
