Tag Archives: bronze keel bolt

Forward floors and keel – done!

Drilling-to-fix-floors-to-the-keel

A major watershed in Dorothy‘s restoration was reached today as Tony drilled 4 silicon bronze bolts into the new floor straps, fixing them firmly to the keel. (see above. Below are the forward floors as viewed from the hatch last May, with mast step removed.)

Forward-floors-before-restoration

This structural repair up forward has been a long-thought through process that began last April (see photos in this news update) as Tony ripped out the floor and straps, pried up the mast step, knocked out the galvanized bolts that were loosely knocking about in half inch holes because the metals had corroded the wood, and began seriously contemplating how to pull together lap joint that had become separated by about 3/8th” from the keel and stem – if it were even possible…

Tony-looks-at-the-floors-and-keelThis last piece of business is quite serious, because all of Dorothy’s spot repairs over the years have been done around this separated lap joint, like muscle tissue building up around an arthritic joint. In fact, Tony expressed his doubts on video last April, saying, “This gap had probably been here a very long time. And someone’s done repair planking, and everything’s been built around that gap, so there’s no way I can actually even cinch that together, to get it back in place. Which is… unfortunate. But I really wish I could cinch this – so these two gaps close together.”

Tony-points-out-gaps-in-lapjointSo the question last May was, if he succeeded in pulling together this lap joint, would that adversely affect the structure built around it? And how could one go about pulling together such a massive gap?

Well, if you know anything about Tony Grove, you should know that he’s incredibly innovative and not afraid to try something he’s never seen work before. So here is the story in pictures, with comments by Tony as he tackled this particularly interesting challenge:

1. The keel bolts and floor/straps holding the lap joint (which connects the keel and stem) were holding no more, and a gap incurred over time with the other repairs around it serving to maintain the gap.

Showing space between keel and stem-Tony Grove

Comealong-and-temporary-bolts

2. The lap joint had spread apart over time and I wasn’t sure it could be pulled back into place. However, I came up with a plan to use two 3/4 in. bolts and a shackle threaded on the outside on either end of the lap joint, this allowed the use of a comealong to pull the 3/8 gap into place. Once this was accomplished I was pleased to see that all the pieces in that area fell nicely back into their original positions.

3. The floor timbers and floor straps all had various form of rot in the forward area around the lap joint. I replaced them with new white oak and that was steamed or cut into shape. The orange colour is just a red lead primer.

4. I then replaced the lap joint keel bolts up forward by first drilling bigger holes in where the original 1/2 in. iron bolts had been. The holes in the wood had enlarged from the old bolts and electrochemical decay. The new bolts are 5/8 in. silicon bronze.

The 3/4 in. bronze bolt holding the forward end of the lead ballast was in good shape so was set back into the boat through a new floor timber.

5. The front end of the lead ballast used to have a wedge in to help fair it, and it must have been banged off at some point. That has been replaced with a new piece of white oak.

So there you have it! One comealong, a few shackles and some bronze bolts later, Dorothy‘s forward area is coming together beautifully. You should come by and see her before she’s all sewn up. It’s going to go fast from this point forward as Tony dedicates himself to getting Dorothy finished this winter.

After all, he’s going to need his shop back for the courses he’s teaching next spring and summer. If you haven’t read up about the new adventures in “The Grove Woodworking School”, head on over to his website to find out what’s happening.

Til next time, T n’ T

Tony-imitates-cinching-comealong

Replacing the first of Dorothy’s floors

From outside Dorothy

Dorothy has been patiently waiting for attention in Tony Grove’s magical woodshop for some time. At last, other work being cleared away, the boatbuilder could begin on her stem/keel and floors, cutting away the 117 year old wood and fastenings, and measuring new timbers and frames.

Filming this process was a bit difficult – or I’m frankly out of practice – because Tony works super fast (even with me slowing him down!) He moves from bow to bandsaw to sander to steambox to clamp station and back again while I’m still setting up my shot! Wonderfully challenging. So if you wonder why there’s a series of similar looking shots from the bow, it’s because I finally found a perch where he would keep coming back and I could observe him without getting in the way.

Dorothy's floor timbers from above

View from small hatch of the stem with keel bolt taken out. Her garboards were actually removed back in October 2012, a process we filmed on our first shoot for “Between Wood and Water”.

Here’s a series of images that hopefully will give you the “1000 words” behind the story. If anyone has any technical questions, Tony will do his best to answer, but as he’s still in the middle of researching, some answers will take a bit longer to get to. But please do write and comment! This is a great time to ask questions because it will inform us a bit on what you want to see in the documentary…

Total shock at how little is holding Dorothy together

Tony expresses his shock at how little is holding Dorothy together….. OK, not really. He was mostly trying to scare me, saying the bow would crack under my weight as he took out these frames! Yikes!

Tobi shooting from the bow

There is barely room for two of us in that bow – Dorothy is very narrow up forward, and this wide-angle lens makes her look beamier than her actual 10 feet.

 

Removing old epoxy from mast step

Tony has just ripped off the mast step, which was covered in epoxy, which made it suspect, but it was actually ok. At least it’s clean now.

Now we can see how the floor timbers fit together

Now we can see how the floor timbers fit together

This old bolt just popped out (which is not supposed to happen). Tony thinks it’s galvanized steel and is original to the boat. It’s been eaten away pretty badly as you can tell, it should be about twice as long.

This old bolt came off super easy, in fact the head broke off. Tony thinks it's a mixture of iron and galvenized steel and is original to the boat.

This is where the bolt was…

Unscrewing keel bolt

This bronze keel bolt is actually in pretty good shape, still has thread but the wood timber its supposed to be holding in place is completely gone.

This was the wood around the keel bolt, now obviously broken down due to electrochemical decay. Here with the new oak timber that will replace it.

This was the wood around the keel bolt, now obviously broken down due to electrochemical decay. Here with the new oak timber that will replace it.

So this is where it’s complicated – or can be. Building new frames and floors for Dorothy requires taking so many angles into consideration, Tony was scribing, measuring, considering, sawing, sanding for a good half hour for each. It was fascinating to watch/film, because he would spend all this time simply looking, analyzing, running the shape through his artistic/boatbuilder brain, and then fly into action and 20 minutes later… the pieces popped into place like they grew there – the first time! Amazing to watch him in action.

The old rotten frame coming out. There was almost nothing holding them to the stem/keel.

The old rotten frame coming out. There was almost nothing holding them to the stem/keel.

Here’s a measuring-to-bandsaw series:

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And then it’s necessary to keep testing them in place. This back and forth could take all day, but was relatively short this time around. Thankfully for the filmmaker and hungry boatbuilder!

Fitting in new floors

The piece on the right (port) will sister the frame going across the floor, which was steamed and bent yesterday.

The piece on the right (port) will sister the frame going across the floor, which was steamed and bent yesterday. These two sister/side pieces popped in for an exact fit – nice when that happens!

And then who doesn’t know how clamps work? Not much to say except they are pretty essential to any boatshop, as I’m learning. As I posted yesterday, Tony has about 50 in his shop, but could always use more. And someone on Facebook responded by saying “there are never enough clamps”. I guess it’s a universal thing…

Clamping new oak for Dorothy's floor

That about wraps our little inside look at the floor timber/frame restoration process. Lots still to come. Tony will be working on Dorothy throughout the summer, aiming to get her back in Victoria for re-rigging by Fall. So there will be frequent updates here, watch this space!

On the weekend I will post more about the Tony Grove special… a steambox that is portable and won’t break your bank!

Cheers, happy sailing (and restoring and refinishing and varnishing and polishing… )

Tobi and Tony and Dorothy