Rope Fenders - Part 1: Materials/Tools/Equipment/Jigs

Fenders come in a mixture of sizes, types and prices. It would be logical to budget for fenders to suit my pocket, however, I really want to make them.

I can't justify spending out for the gear and materials I'll need, but I have to make them: I've always wanted to play with rope. Already I have spent hours watching videos of professionals at work and from this devised a project plan of which this is Part 1.

1. Materials For six large fenders I need 100 metres    of  12 mm dia. Manila rope (328 feet and 1/2 inch dia)................................................................ £ 120

This is good quality rope in a natural Fibre (fiber): it comes from a type of banana tree that grows in Ecuador, Puerto Rico and the Philippines. It offers a long working life and is totally bio-degradable. 

2 Tools & Equipment

Marlin-spike ................................................................. .£16.25

Swedish Stainless Steel Fid ............................................£18.50

Strong and sharp scissors ................................................£22.41

Portable Hot Knife or Rope Sealer .................................£24.40 

11mm Stainless Steel Carbine Hook - Wide Opening.... £ 6

2.5mm x 19mm Bright Zinc Plated Steel Chain .............£ 1.12

5mm Stainless Steel Jaw and Jaw Swivel........................£ 1.66     

                                                          £ 90 .34

Marlin Spike & Sheath

Marlin Spike & Sheath

Scissors

Swedish Fid

Portable Hot Knife 

Stainless Steel Carbine Hook

Bright Zinc Plated Steel Chain

Stainless Steel Jaw and Jaw Swivel

3. Jigs  Having seen countless videos of the professionals in action led me to designing my own version of the jig. Most jigs I saw had three wooden dowels glued into a base; each size of fender having its own unique jig.

I noted that at some stages of fender manufacture, the constant movement of the jig made the task more difficult. 

My design should, I hope, give definite advantages.

My Own Jig Design and Self-Build 

The jig I designed and made has one fixed dowel peg and two bolt assemblies. The bolts can be removed and moved to other sets of holes (yet un-drilled) to accommodate other size fenders. In other words a universal jig for all sizes of fender.

I have designed the two bolt assemblies to protrude two inches below the jig. This provides three options for the jig to be held stationary during manufacturing.

     *  Use the bolt protrusions like a bench hook

     *  Hold the bolt protrusions in a bench vice

     *  Drop the bolt protrusion into holes on bench top

A Carpenter's Bench Hook - ignore saw

4 Cost Comparisons for Six Large Fenders.

Total cost = Materials + Tools = 120 + 90 = £210

Purchase Cost Ready Made Range = £240 - 320