A twenty foot sheet of plywood is a beautiful thing. It took more than a little work though.
If you remember, I was originally going to use puzzle jointed sheets of plywood to make the long sections I needed for the planks. Because of cost and schedule I decided to go the old fashioned way and use scarf joints. Cutting the scarfs was easy enough. I have made a 6:1 jig for my circular saw that leaves a fairly decent scarf. Once cut it only takes a few minutes to tune it up with my block plane. From there it was a matter of gluing up the joints.
As you can see I used every bit of weight I had in the shop to clamp up the sheets. This was the end result.
Large voids and big gaps in the panels due to not enough clamping pressure. Cussing and moaning, I pulled out my track saw and proceeded to remove the offending joints. This is the rig I used for round two, jointed 2×4’s and quick-grip clamps ensured there was enough pressure to do the job.
The end result?
A satisfied inspector.