Building peterson's schooner "susan" #12

[RodB]

This is the continuation of the Thread on "Building Peterson's Schooner "Susan"... this is the 12th separate thread in a continuing series.

Here are the links to previous segments on this thread.... Note.. a few of the threads in the first 4 segments are missing some images because SonyImagestation closed down... and I did not redo the image links. Segment #2 and #3 are particularly missing links.. .. I have a pdf file about 80mb in size (consists of segment #1 thru #6) that I can send you if you send me your email address via pvt message..... I can send it via www.yousendit.com

Thread #1 First thread (Images of "Susan" sister ship and basic parameters...set up of strongback and frames)

http://www.woodenboat.com/forum/showthread.php?t=11087&highlight=Building+Susan

Thread #2
http://www.woodenboat.com/forum/showthread.php?t=51863&highlight=Building+Susan

Thread #3
http://www.woodenboat.com/forum/show...Building+Susan

Thread #4

http://www.woodenboat.com/forum/showthread.php?t=62936&highlight=Building+Susan

Thread #5

http://www.woodenboat.com/forum/showthread.php?t=82391&highlight=Building+Susan

Thread #6

http://www.woodenboat.com/forum/showthread.php?t=77658

Thread #7

http://www.woodenboat.com/forum/showthread.php?t=82391

Thread segment #8

http://www.woodenboat.com/forum/showthread.php?t=83864

Thread segment #9

http://www.woodenboat.com/forum/showthread.php?t=90162

Thread Segment #10

Pg 1
http://www.woodenboat.com/forum/showthread.php?t=96078

Pg 2
http://www.woodenboat.com/forum/showthread.php?t=96078&page=2

Thread segment # 11

Pg 1 http://forum.woodenboat.com/showthread.php?108140-Building-Peterson-s-quot-Susan-quot-11

Pg 2 http://forum.woodenboat.com/showthread.php?108140-Building-Peterson-s-quot-Susan-quot-11/page2


This segment will begin with the pouring of the keel, which is approximately 4,500 lbs.

First I thought I'd show the mold which is used in the casting process. This mold was reinforced and coated on the interior to withstand the hot lead better. See previous thread for these details.

http://i40.photobucket.com/albums/e239/Prestoboat/Misc%202009%20Aug/keelmoldconst-72.jpg


Now here is the basic setup with the female mold in the hole in the ground, with doubled chains on both ends to enable the keel to be lifted out of the ground after casting. The ground was leveled here with a bag of cement dumped on top to make for easy minor adjustments for setup. The tank was purchased in a scrap yard and is constructed of 1/4 " steel. The hole cut in the top is wide enough to throw in lead and the cut out plug will be used to close her up while heating the lead. Its important during the melting process to minimize the loss of heat from the tank. The height of the tank was simply set up so that when the pipe was rotated down it would be placed precisely where the the molten lead needed to pour in via gravity.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/setupfortankbricks-72.jpg

The mold closer up. NOTE the 1" wood dowels precisely located and locked into place to produce holes for the one inch threaded rods that will hold the keel to the hull. The bottom of the wood dowels are set in a small wood block that will end up producing a recess at the bottom to fit the large washers and the nut at the bottom of the keel. See following photo to see this...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/dowelendblockinmold-72.jpg

Working on the setup... she's coming along...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Moldsetupwithtank-72.jpg

Almost there.... fire to build soon...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/tanksetupaddangle-72.jpg

More setup... the tank filled with purchased lead and billets Bob had molded over the past few years...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Tankportloadedlead-72.jpg

Continued...

RodB

[RodB]

More of the purchased lead ready to be poured in via a trough later on after the initial pour starts....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/shotbagsonsawhorses-72.jpg

Heres the modified cutout of the tank which will act as a lid to contain the heat during the melting process...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/tanktopwweldedtabs-72.jpg

Here you see about 3/4" of lead shot poured into the mold before we fire up the tank... this small layer of lead will melt easily as the molten lead pours into the mold. This just saves some time while taking advantage of the heat the molten lead will retain.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/leadshotinbottomofmold-72.jpg

I thought I'd add this one of Bob adding a bit more lead which was earlier, but shows some context ...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/bobloadingled-72.jpg

Believe it or not... I help Bob with the work, it just looks like he does it all. I'm the one who constantly is grabbing the camera... in between tasks...:D

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/loadingleadtoboards-72.jpg



Con't...

RodB

[RodB]

I thought I'd show a good shot of the buried mold before all is covered with fire and smoke and metal sheets, etc.... 6 x 8" stock will be threaded through the chains after casting and used to lift the keel out of the ground.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/moldingroundwchainsetc-72.jpg

Starting the fire... which will be spread to cover the entire tank...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/tandkfiregoing-72.jpg

The fire going good for awhile... ... melting lead good now. Initial pour should be soon. Note the sheet metal that was wrapped around the side and end to contain the heat better.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/fireblazingontankinitial-72.jpg

Note the bricks between the fire and the side of the mold... making sure the mold itself doesn't burn. Also note the roofing torch at the upper right corner which is used to heat up the pipe which tends to have a lead plug in it keeping the lead from pouring. Note the tin foil on the top boards of the mold to keep the wood from burning...


http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/pourabouttogo-72.jpg

This gives you a better perspective on the layout... and the heat... the pipes they are using are 10 feet long and its still quite hot. We are about to start adding more lead... in the form of lead shot... The lid is heavy but easily handled with one of the pipes....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/topliftedoff-72.jpg

Heres a sheet metal panel folded into a large triangle ... trough/pipe/slide... in which we can dump lead shot into and it will flow into the melting tank "from a distance". Have you ever poured lead shot down a slide for fun??? It works very well.... Note the clamps holding the slide in the shape of a triangle... BTW, there was some hot dangerous gases coming out of the end of that slide when pouring lead into it... respirators and a good sidewind helped a lot.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/leadloadingtroughsideview-72.jpg

Continued...

RodB

[RodB]

Here, Bob is using the roofing torch to heat the drain pipe so that the lead can drain from the tank. The initial part of the pour is about to start. Once the molten lead is in the mold, you have plenty of time to melt more and pour more... as the lead in the mold retains lots of heat and stays molten for quite a while.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/bobheatingtipofpipe-72.jpg

Heres another view of our "slide" for pouring more lead into the melting tank...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/leadloadingtrough-72.jpg

Finally the roofing torch melts the lead in the end of the drain pipe... and "WALLAH" the lead begins to pour out into the mold.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/leadpouringout-72.jpg

Here we are getting closer to the end... still melting lead.... still pouring...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/leadflowcloseupnice-72.jpg

Hotter work at the end... still heating the drain pipe.. some of the mold top has caught fire a little... Fire burning great...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/fireblazeporteminent-72.jpg

Alright... so the lead pouring was done... I left and it cooled for a couple of days. Bob then threaded 6" X 8" beams through the chains at both ends of the keel and used floor jacks to lift the keel out of the ground... sliding 4X4's under the keel mold.... holding it at ground level. Next Bob removed the wood from the keel and turned in on its side so that he could clean out the wood blocks at the bottom and fished the holes created by the 1" dowels by running a 1" drill bit through the keel directly where the dowels are positioned. Bob borrowed a small front end loader to place the keel in the shop beside the hull... Thats all folks for now... sorry I don't live there... so that I don't miss any photos of the entire process....:d

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Keelsetttingbesidehull-72.jpg

con't...

RodB

[RodB]

Note the cleaned out holes for the threaded rod... and that the opposite end of the keel lost some lead due to a leak at the end of the pour. .The wood burned some there causing a leak, which let some lead escape from the top of the mold. the loss of lead at the other end will be faired and leveled via epoxy.... before she is bolted up. Heating the drain pipe with the roofing torch was difficult in that ilt was hard to avoid burning some of the wood framing atop the mold. This is no big deal as the top of the keel will be faired and fitted and the other surfaces of the mold are perfect. The surface against the hull will be faired and make no difference.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Keelcastedendon-72.jpg

Heres a closeup of one of the holes in the keel drilled for the stainless or monel threaded rods.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/keelholecleanedout-72.jpg

A slightly closer shot of the keel...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Keelsittingonfloorprofileangle-72.jpg

More to come....... next the keel needs to be planed and faired with the top surface filled in where needed. Then she will be bolted up to the hull... more pics to follow....

By the way, this is the 4th or 5th keel Bob has cast.... and he says its his last. He saved about $6K by doing it ... he spent about $3K but had collected at least 2000 lbs of lead from tire stores and casted them into ingots....

Enjoy...

RodB

[johngsandusky]

Excellent, thank you.

[RodB]

Thanks John...

I thought I'd show this pic since it shows the scope of the fire we used to melt the lead...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/secondpourtankcoals-72.jpg

R

[ucb4ume]

Thanks for sharing. Keep the pictures coming.

[donald branscom]

When looking at the pipe the liquid lead was supposed to come out of my first thought was that it was way too long and the 90º elbow would slow down the lead and cool down inside of that pipe before it got to the mold.

That pipe needs to be very short and straight to the mold.
You can get lead too hot.

[SScoville]

By the way, this is the 4th or 5th keel Bob has cast.... and he says its his last. He saved about $6K by doing it ... he spent about $3K but had collected at least 2000 lbs of lead from tire stores and casted them into ingots....


RodB

Am I reading this wrong or are you saying that a lead keel like this would cost $9,000.00?

[RodB]

That pipe needs to be very short and straight to the mold.
You can get lead too hot.

Donald... it worked fine...


Am I reading this wrong or are you saying that a lead keel like this would cost $9,000.00?

Well, lead is about $1.00 per pound and casting, if you only supply a drawing, is about the same... I checked with Bob, he said if you just supply a CAD drawing to the foundry, your cost will be about $2.00 per pound. If you supply the mold, I'm guessing the cost would be less.

Obviously, the price of lead varies....

RodB

[riversailor92]

Great to see some new pictures! I have been eagerly following this story for some time now and I was beginning to get discouraged these last few months but I'm glad to see my discouragement was misplaced. What is the total build time on this project now? Do you have an official start date written down somewhere?

[Bernadette]

Believe it or not... I help Bob with the work, it just looks like he does it all. I'm the one who constantly is grabbing the camera... in between tasks...:D



yeah right...as if!!! seriously i know the feeling. i have to stop to take pictures of our work too and im seldom in front of the camera.

anyhow, no amount of pictures can really convey the hot hard work melting and pouring a lead keel can be. glad it all worked out for you.

[Eric D]

Nice job Bob!!! Nice to get that much done, hopefully it is all smooth sailing from here to launch. Any projected dates?

[BobAlbers]

Thanks for the comments! It was great to get the keel done....thanks to Rod and another co-worker for the help pouring.....it is a messy, stinky thing to do!
Unfortunately, the mold burned at the top (due to me burning it with the roofing torch) and it sprung a leak before the pour could finish....this left about 1-1/2 inches below the top....so now am working on a "fill piece"......
Anyway, all said and done it will work out fine.....will be using 1" bronze, through bolted.....there are 12 ea....
As far as "projected launch dates"...that's anyones guess, hopefully next fall???....it always seems the last 10% takes 90% of the time!!!! Still have rudder, spars/rigging, electrical, finish work etc. to do......
-Bob

[Sailor]

We have a comment about the 90/10 division of labour in our business. The "Ten Percenters". As in it's always 10 percent of your people who are the cause of 90 percent of your administrative burden. Or I guess you could compare it to the power required to increase speed. It increases exponentially as you increase your speed. Either way, the anticipation we have built for this boat to be launched has lately been increasing exponentially as well. Beautiful work and we look forward to seeing your next build. RodB will be documenting it right! ;)

[riversailor92]

Well its been near two months since anyone's last post so I'd call this a worthy occasion for a Bump and a half on this thread! Bumpity Bump-Bump indeed.

[Eric D]

funny river, just today I was wondering the same thing so I will raise you a bump.

[BobAlbers]

Hi all.....thanks for the bumps and wondering "what's up".....things have still been progressing slowly lately....but there has been some progress..
The lead keel is now underneath the boat with bolt holes drilled.....I ordered the bronze rod for the bolts (man, that was pricey)..and am working to get the material to the machine shop for threading...
I've also began the rudder...the fittings will need some machining as well...
Rod has been busy repairing some other boats and he and I have not had a chance hook up lately....I'll get with him soon to get some more pics posted.....
Once the keel bolts and rudder are complete I will begin spars.......getting anxious now as I can see completion coming!! not sure when, but at least can see it!!

-Bob Albers

[Thad]

Cheers, thanks for the report!

[riversailor92]

I'll second what Thad said. Sounds like things, although still not done, are at least looking pretty. Can't wait to see some rudder pics. Isn't it just so exciting when you finally start the spars and rigging? I see that you guys installed an engine sometime ago but I was wondering if you have a shaft and/or prop yet? Exciting stuff!

Keep on keepin' on,
- Cam

[RodB]

So, here we are with the fabrication of the rudder and the keel bolt up in progress...

The Bronze 1" rod's back from the machine shop... some quality work...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/bronzekeelbolts-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Bronzerodnicesho-72t.jpg

The keel has been drilled out (where the wood dowels were in place to receive the keel bolts. All is aligned and ready for the "bolt up", only the bedding epoxy between the keel upper surface and the hull to be applied before final bolt up.

The keel in place with the hull strapped in for lifting by the ceiling trusses.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Susankeelinplaceboatliftrig-72.jpg

The lifting setup wide view... Those engineers sure figure out this stuff easily...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/keelsetupwideview-72.jpg

A floor view of the rig...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Keelinplacehulllifed-72.jpg

Heres the rudder fabrication in progress. The surface has been sheathed with Xynole .... All the hardware has been machined for this, now inletting the rudder and the hull to be finished...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20start%2012-11-2010/Susanrudderdryfit-72.jpg

More to come...

RodB

[Sailor]

I admit I'm salivating!

[A.Greever]

I admit I'm salivating!

About the shop or the boat?

I like both!

[P.L.Lenihan]

I admit I'm salivating!

Once yer all done with that Daniel, start working on your dream boat now ! Time is fleeting and you ain't getting any younger!





Beautiful pictures,as usual, RodB! Everyone must be getting anxious to see her hull all painted soon! I know I am!!




Cheers!


Peter

[Eric D]

Tom,
thanks for the update. That bronze sure looks sweet!!!
I agree with Peter about seeing it in paint!!

[RodB]

Another shot with the rudder body all glassed with Xynole...and fitted to the hardware more or less. The rudder shaft is in position and most of the shots on this update will be in the cockpit...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/rudderanglereflectiondryfit-72.jpg

And here the rudder shaft coming into the stern through the fiberglass lined hole.... the steering gear is on top here... blury...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/ruddershaftinFGliner-72.jpg

The steering gear by itself atop the rudder shaft... Note: support bracket in front which will have a wood support system installed around it. Bob said this type of steering gear is quite common and is a solid performer....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/helmgearcloseupforwardend-72.jpg

A closeup of the steering gear atop the rudder shaft.... with coupler and support for bracket... additional shaft made to link to the helm wheel. Note steering gears like this can be very expensive ... like $800 plus or minus...but Bob got lucky and found one very reasonable a couple of years ago.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/steeringgearcoupleretccloseup-72.jpg

Part of the machine shop work Bob has had to get done to complete the rudder system....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/bronzeshafthelm-72.jpg

The coupler connecting the steering gear to the wheel... note coupler and shaft are "keyed"....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/keyedcouplerandshaft-72.jpg

con't

RodB

[RodB]

Closeup of the wheel hub, Bob said this helm wheel was still made but he found this one on ebay... for a fair price.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/helmhubcloseup-72.jpg

A wider shot showing more... in perspective.... Some fitting and fabrication for the forward end of the steering gear hatch still needed ... the rudder shaft has to be shortened one inch... so off to the machine shop one more time.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/helmfittedroughwheeltoo-72.jpg

Another perspective.... Note: when at the helm the skipper can stand in front of the wheel steering with his hands behind him, of sit on either side with one knee behind the wheel, or straddle the steering gear hatch and steer facing forward.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/helmpartsinpositionroughwide-72.jpg

OH yeah, I forgot... Bob's latest addition to the shop... a restored Radial Drill Press... Rockwell made it...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/drillfrontviewnice.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/drillwideboatbkd.jpg

This Walker Turner made by Rockwell was really restored very nicely....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/drillbobspulleysrestored.jpg

Next... completion of the rudder assembly both interior and exterior... and then completion of the engine installation, etc. The mast fabrication should begin about August or so...

RodB


RodB

[Bernadette]

I admit I'm salivating!
yeah! me too. and im talking about Bob's shoulders!!!
oh yes, i forgot. this is a wooden boat forum. yeah...the boat stuff looks good too!!!

[Saltiguy]

Thank You for this wonderful thread! It is truely inspiring, and I look foreward eagerly to each new thread!

[Lucky Luke]

yeah! me too. and im talking about Bob's shoulders!!!


Here comes "our" girl....:rolleyes:

[Sailor]

It's back in progress again! YAY. I missed this thread of late.

[RodB]

Update... Steering assembly...

Here Bob finished the steering gear assembly and has started on the deck caulking...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/susansteeringgearclosedone-72.jpg

Another angle...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/susansteeringgearrtview-72.jpg

A wider view, note the steering gear hatch allows one to helm by straddling the wheel shaft facing forward... or by sitting on either side of the helm ... Note: Bob has started the teak deck caulking with some areas about ready for sanding.... and others sanded already.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/susansteeringcomplete-72.jpg

Note how dark brown the Osage hatches are after many months aging with linseed oil on them... that bright yellow is all gone....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/teakdeckscaulkingmid-72.jpg

Final engine installation details are next.... with mast fabrication in the near future.

RodB

[McMike]

Keep em comming.

[Sailor]

I love the look of that aged Osage Orange. I wonder if I can get that stuff around here? Keep up the great work. I was salivating over the boat AND the shop. Mines nice but not like that one.

[RodB]

Oh yea... heres Susan currently.... from the bow...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanbowviewhull74-72.jpg

[Sailor]

Colour, now for the rest of the hull. Great work. Can't wait to see her afloat.

[riversailor92]

Hey, looking great! I have been following this project for some time and I had to admit that I have been living vicariously through you as I do not have the time the space or the means to do a project like this myself. I was looking back through some of your older threads and I had a question about the planking process. I read (but could not see the photos) that you strip planked, then, cold molded the hull. I greatly admire that you found a way to make a hull with a beautiful shape but without all the trouble of carvel planking (all the spiling, etc...), something I think Phil Bolger would have been proud of. What I was wondering was could you have just put a layer or two of fiber glass over the strip planking and called it a day? Was the cold molding a necessity or just something you wanted to do? I'm not criticizing, just wondering.

Thanks very much and keep up the good work,
- Cam

[RodB]

I was wondering was could you have just put a layer or two of fiber glass over the strip planking and called it a day?


Thats a common idea... and is more often used in smaller boats.... however, when folks are building boats on the heavier end of the displacement spectrum... many choose strip/ cold molded because it produces a really strong hull without the extreme labor required for just straight cold molded construction. What you are asking about has been described as one of the methods that comes close to building the lightest hull per weight unit unit strength.... and is described in detail in "Sheathed Strip Construction Scantlings Rule" by MacNaughton Associates, Inc. and they also offer a well written essay called "The Sheathed Strip Alternative", which makes the case for sheathing a strip planked hull with the sheathing as a vital structural part of the construction. This supposedly makes for the lightest hull you can build....and according to the Scantlings Rule on this method of construction, is plenty strong as long as the fiberglass sheathing is applied in proper thickness on both the interior and exterior surfaces. The fiberglass supplies transverse strength across the strip plank joint and the strips supply the longitudinal strength fore and aft... Check with MacNaughton and Associates and order these publications if you are interested.

What I think it boils down to is that when building a classic design, weight, weight distribution, etc play an important part in how a finished boat will perform and behave in the water. People build classic designs because that particular design was a masterpiece... in looks and performance... they do not want to lose those wonderful characteristics.

In Susan's case, Bob Albers already knew his hull was going to be stronger and lighter than the original and was considering his alternatives in trying to get the weight up to insure performance was close to the original. Remember, Bob is a mechanical engineer at "Boeing... so he spent lots of time lofting/redesigning Susan to her exact dimensions in epoxy composite construction... Strip cold molded was a method to produce a "bullet proof" hull at a reasonable weight ... a monocoque structure with tons of strength. The ballast for Susan here was increased several hundred pounds and the cabin sole is Ipe... ways and ways to increase weight... and make for a good overall weight distribution. Perhaps Bob will chime in here in the near future and offer some more insight to his construction choices...

RodB

[riversailor92]

Bumpity-bump-bump. This is by far one of my favorite projects on the WBF and I go through such withdrawals between postings. :(

[Sailor]

I think the only thing keeping this thread from getting a sticky is the time between posts but if you're working at that calibre... well you can't rush a master.

[BobAlbers]

Hi all...
Thanks for the interest...not a whole lot of progress lately due to busy work schedule and the darned heat!!!
It's been 100 degrees or more for over 2 months now....impossible to do any finish work.......wearing thin...
Anyway, I'll be back at it this week.....still finishing up engine details/install - got the prop shaft made etc.
It's a little frustrating when completion is getting in sight...although still have lots to do...
electrical/plumbing details/spars/rigging/painting.....
Once there is more progress worth photographing Rod will be out to take some pics...

Respectfully,
Bob

[Thad]

At least you haven't burnt up! Thanks.

[Eric D]

Bob/Rob, thanks for the updates,

Bob, I love the idea you had for lifting points in your shed.

I will most definitely steal that idea when my next shed is built.

Just curious, what did you spec them out at in terms of weight capacity? Thanks.

[RodB]

If I remember right, I think Bob told me the two trusses were capable of lifting 12-14K lbs...

RodB

[riversailor92]

Thanks for the update! Much appreciated for all of us going through withdrawals. Sorry to hear that progress has been slowed by the dreadful weather, but hope is most definitely in sight. It's been getting rather chilly up here in Maine, I'm sure you'll be sharing the wealth soon.

Can't wait for more pictures!

[riversailor92]

Bump and a half!

[RodB]

Ok... heres some more progress... Bob has been busy since the heat went away..... Teak decks finished, rudder assembly, steering gear, cockpit trim, etc ...........


Rudder and steering gear completed... rudder attachment completed and rudder primed. Hull sanded fair and primed with two coats of epoxy primer from Smith and Company.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Rudderinstalledprimed-72.jpg

Note the 1" thick strip of Ipe as a protective skid plate extending from the rudder to the keel.... glued on with 5200 so it can wear off over a long time and be replaced easy enough...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanabrasionstripkeel-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/steeringgeardonenice-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanhullprimed-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanbowonprimer-72.jpg

Bowsprit partially shaped... ready to be dry fitted....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/susanbowspritbobholding2-72.jpg



RodB

[RodB]

Bowsprit drawings from plans...


http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/SusanBowspritplansprofile-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/bowsprittopviewsplans-72.jpg

Spacer to be installed at the bottom of the bowsprit to center stick up and down...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Bowspritbarewoodfitted-72.jpg

Wider profile view... the hull looks more balanced now...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Bowprofileprimed-72.jpg

And here, see the sampson post fitted and bowsprit laying in place...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/sampsonpstbelow-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/bowspritsamppostwide-72.jpg

Continued...

RodB

[RodB]

This photo shows a cross section of the deck with underply, epoxy/glass layer and teak deck installed with epoxy...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/crosssectiondeckandteak-72ANN.jpg

The teak decks came out great using TDS (Teak Deck Systems) black caulking. Initially Bob Albers started with tongue and groove teak stock and milled it to achieve his slots etc. A thin piece of tape had to be stuck down on the bottom of each slot/joint so that the black caulking only stuck to the sides of the grooves...not the bottom. This allows movement that maintains the deck nicely. Here, the teak contrasted with the painted bulwarks looks great.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/cockpitsteeringlattice-72.jpg

These shots besides showing the teak also show the cockpit floor teak lattice plus the controls and gauges for the engine. Note the osage trim on the hatches inside the cockpit which will darken to the dark brown shortly and match the rest of the trim and hatches.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Cockpitlatticeengingcontrols-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/enginecontrolsswitch-72ANN.jpg

This shot shows the "offwhite" cabin top and the wood stove smokestack...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/foredeckbowspritcabintop-72.jpg

A nice view from the loft... shows the overall look.... The aluminum "U" shaped pipe will be shortened and completely covered with braded line to look "period" for such a schooner.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/overhead2bulwarkspainted-72.jpg

RodB

[RodB]

A nice view of the decks etc from the bow...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/topsidesdecksbulwarkdone-72.jpg

This shot shows one of the stern oak cap rail joints with a couple of coats of Cetol.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Caprailsterncloseupjoints-72.jpg

I like how nice and brown the Osage has oxidized over the months with only linseed oil applied...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/foredeckhatchosge-72.jpg

The masts will be coming up very soon.... Heres some 32 foot Douglas Fir 2X6's to start inventory...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Mast2X6s-72.jpg

RodB

[ucb4ume]

Thanks for the update Rod. She's really starting to come together. I see light at the end of the tunnel.

[riversailor92]

Absolutely fantastic stuff guys! I am completely and utterly jealous! Keep up the good work and thanks so much for continuing to entertaining us!

[Sailor]

I'm in awe. I LOVE the Osage and how it turns dark so beautifuly and so quickly. I wonder if it's available here in Nova Scotia. I could certainly trim a boat in that and not feel the least bit bad about it.

[riversailor92]

Lions, tigers and spars, oh my! Looking good gentlemen.

Having followed this thread for a number of years and having fallen in love with Murray G. Peterson's "Susan" schooner design I can't help but feel like I'm watching my own child, or at the very least a favorite niece or nephew, growing up. I continue to be amazed by the beauty of this design and the excellence of your craftsmanship. Please keep entertaining all of us who follow this project religiously.

Thanks,
- Cam

[SchoonersRUS]

I just read the whole thing. Very beautiful boat, well made. A lot of yellow pine, though. Some people say it's not good to use, but seems like it turned out just fine. Excellent workmanship.

[RodB]

A little progress.... Bob painted the topsides a couple of coats... "off white".... shes looking very clean...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/hullpaintedsternside-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanhullsternview-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanbowspritprofile-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susantopspaintedhull-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanhullrtsidepaintedrubrailtrial-72.jpg

She's sure going to be pretty....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susansailplandrw-72.jpg

RodB

[RodB]

Other works underway...


Booms and such....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/boomsrough-72.jpg

Birdsmouth trial section (bottom and top of mast will be filled in solid....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/birdsmouthtrialpiece-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/birdsmouthtestcloseup-72.jpg

Love the smell and dry heat of the wood burning stove... with a fan is even better...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/STovebobsshop-72.jpg

Till later....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Susanhullpaintedfloorshot-72.jpg

[P.L.Lenihan]

This build just keeps getting more stunning each time you post an up-date Rod. Your excellent pictures tell a perfect story of craftmanship.Thank you for the up-date and bravo to Bob for allowing us all to follow along!!


Cheers!


Peter

[RodB]

Thanks...

There will be a navy blue cove stripe and the bottom will be red most likely.... standard bottom paint.

R

[sailboy3]

Gorgeous.

[Larks]

I'm with Peter, this just keeps getting better, I've thoroughly enjoyed your threads Rod.

And I love that shed!!!

[Sayla]

Can't get enough of it - great looking colours
- wish I were working away and smelling that wood stove myself

sayla

[Sailor]

+1, can't get enough of this thread. Looking forward to seeing her completed. And starting my own Peterson Schooner one day I hope.

[Thad Van Gilder]

A very sweet boat!

[domecreek]

Great Thread !!!! Thank you for sharing. You indicated that you would be putting hinge(s) on you hatches. Have you done that yet ? I would certainly appreciate some close-up photos of your hinge installations and where you sourced your hinges from.

[riversailor92]

How are those spars coming? I can't wait to see them standing tall!

[darroch]

Thanks to you both for this build thread. I'm always impressed by how much work gets done between threads on this one. She looks just gorgeous!

[Bernadette]

she is looking just beautiful. thanks for posting the photos.
im envious of such a beautiful boat. great work! yum! yum! i hope one day our two boats can raft up for a peterson "get together" to celebrate both the designer and their respective builders.

[USS Flasher]

Summer Bump

[HarryH]

Rod, or Bob-

Perhaps I missed it, but will ask in case not: What paint mfg. and color is the hull "off white"? I've been contemplating some shade similar....

Thanks..

[BobAlbers]

Hi All,
well it seems life has gotten real busy lately and progress has come to a stand still......
funny how there is not much left to do and time is now hard to find!
Anyway, I hope to get back to work in earnest soon.....Rod has ben bugging me for some progress too....masts and rigging are next..

Hull paint is Rustoleum Topside Marine - color Oyster White....I like the simplicity and less cost of enamels...

-Bob

[beernd]

It is incredible that I missed this thread, beautyful boat.

A pity that the links to the other threads are not working anymore I would have liked to know a bit more about the construction method.

[RodB]

OK... start her up after a long hot summer... continuing with the spars... the booms and gaff are solid and done... here the masts are being fabricated....

Birdsmouth staves all scarfed and milled, ready for glueup.... (Doug Fir)

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Stavesformastalreadywithbirdmouth-72_zps799d396b.jpg

8:1 Scarf

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/scarfcutonstaves-72_zps39763c4d.jpg

Spar stave cradles.... for just holding the staves in position till clamped up for gluing....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Cradlesformaststavesgroup-72_zps01f8d80a.jpg

Staves in cradles ... dry fitted...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/maststavesdryfitincradles-72_zps79b8dc6d.jpg

This pic illustrates how the drill holes allow room for the "corners" of the staves...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/stavesincradlesverycloseup-72_zps2a04814c.jpg

This shot shows size perspective and length of spar bench....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Stavesaloneonsparbenchandbob-72_zps651c84d4.jpg

con't

RodB

[RodB]

This closeup shows the final staves from 2 by Doug Fir stock planed just a bit on each side... clamped in place... Milling done with the table saw.

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/MastStavestiedendon-72_zps0209f222.jpg

So, changing channels... lets move the the Bowsprit... Whisker Stay installed for view...

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/bowspritonesidestayprofileangle-72_zps91c2ec7b.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/bowspritandsidestay-72_zps036d21e1.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/bowspritfromgroundonsidestay-72_zpse6873de2.jpg

Note galvanized cable completely wrapped in tarred nylon twine....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/wrappedcableendbest-72_zps877facc1.jpg

Closeup of the Cranse Iron and stay end....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/bowsprittipcablecloseup-72closer_zpsc68bb3ab.jpg

Continued...

RodB

[RodB]

Whisker stay connection at the hull....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/turnbucklesidestayofbowsprit-72_zps2c6bc7ea.jpg
Continued...

One of the bronze jib winches Bob found on Ebay....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/jibwinchandcleatoncabintop-72_zps2f4b0b20.jpg

Placed for viewing....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/jibwinchwithcleat-72_zps0f2a33dd.jpg

Wider view....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/jibwinchandcleatplacesfortest-72_zps02925110.jpg

A better shot of the mast staves dry fitted in cradles....

http://i40.photobucket.com/albums/e239/Prestoboat/Boat%20images%20June%2011%20start/Maststavesdryfittedincradles-72_zpsf824c0c8.jpg

More to come later....

RodB

[johngsandusky]

Way cool.

[Sailor]

Nice. The home stretch is coming up. Looking forward to seeing more of this.

[riversailor92]

WELCOME BACK. Missed your pictures, thanks very much for posting again!

[Sailor]

Rod,
Any updates for us?

[RodB]

Update.... Update...

Continuing with the masts... here you see the mast bases shaped to fit their perspective positions...

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/Mastbasescloseup-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/mastbasesclosewide-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/Susanbowandmastsbeside-72.jpg

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/Susanmastsbesidehull-72.jpg

The original Susan has towing bitts for cleats on the stern for the mainsheets... Bob was working on these yesterday... here are some pics...

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/portbittcleatdeckside-72.jpg

Bronze rod installed in Doug Fir stern bitt....
http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/bittsamsonbronzerodcloseup-72.jpg

Continued...

RodB

[RodB]

Heres the bitt dry fitted with hawse pipe (chock) shown but not installed...

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/Samsonbittandlead-72.jpg

Here both dry fitted....

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/Susantwinbittscleats-72.jpg

Wider shot...

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/Bittswbronzerods-72.jpg

I still have a thing for Bob's radial drill press...

http://i40.photobucket.com/albums/e239/Prestoboat/May%202012%20uploads/RadialDrillpressnice-72.jpg

More to come later...

RodB

[Sailor]

More about that drill press? Looks like it could do a whole lot more than any drill press I've ever used.

[riversailor92]

Very nice stuff as usual! Keep it coming!

[Rapelapente]

Obviously the transom can't wait for gold leafed letters ;)

Thanks again for sharing your beautiful work.

[riversailor92]

Bump!