searching for a Bob Smalser article

[capt jake]

OK, I can't make the 'great googly' thingy work. Bob did a documentary on rebuilding his dory. Specifically I am interested in the bit he posted about the lead weight he cast for the rudder.

Thanks,
Jake

[kc8pql]

Here's a search thingy that someone posted a while back that does work:
WoodenBoat Forum Search (http://www.handforged.net/wbfsearch/)

[capt jake]

OK, thanks. I found the article but not the answer I was looking for.

The star shaped lead that was cast in the rudder of his gunning dory; was it cast in place?

[Bob Smalser]

That detailed article got ate in the forum's server changeover.

The lead is cast in place in a dovetailed thru-mortise:

http://pic3.picturetrail.com/VOL12/1104763/6490387/81276763.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81276782.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81276798.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81276937.jpg

The lead shrinks and is tapped back into the dovetailed mortise:

http://pic3.picturetrail.com/VOL12/1104763/6490387/81276961.jpg

http://pic3.picturetrail.com/VOL12/1104763/7711190/101677609.jpg

[ 09-22-2005, 01:35 AM: Message edited by: Bob Smalser ]

[Bob Smalser]

More....note the dovetail bit:

http://pic3.picturetrail.com/VOL12/1104763/6583947/84781857.jpg

Get it level before pouring...I'm using automotive gasket paper beneath a wood block as a bottom seal:

http://pic3.picturetrail.com/VOL12/1104763/6583947/84771679.jpg

Pour it overfull because it will shrink substantially:

http://pic3.picturetrail.com/VOL12/1104763/6583947/84771686.jpg

http://pic3.picturetrail.com/VOL12/1104763/6583947/84784155.jpg

[ 09-22-2005, 01:44 AM: Message edited by: Bob Smalser ]

[capt jake]

Thanks Bob. In addition to the gasket paper, it appear as though you have applied some sort of past around the perimeter of the pour. The white looking 'stuff'; what is that? smile.gif

[Bob Smalser]

Chalk to keep the wood from burning.

Waterglass (pottery or casting store) works better. Swirl the lead around in the ladle to cool before pouring. If you reach the magic point in a small pour where the lead is as coolest as it can be and still fill your mortise, you don't need either.

Also notice oak primed with red lead didn't need any further protection in a pour that small.

[capt jake]

Chalk? Wow, I though that was al replaced with dry-erase markers. ;) Seriously, a good tip! smile.gif

I assume the dovetail/router is a free-hand operation, as those bits have no guide bearing on them.?

I need to add about 3# of lead to my rudder. I will be pouring the lead into Honduran.

Any more tips?

[Bob Smalser]

Originally posted by capt jake:

I assume the dovetail/router is a free-hand operation, as those bits have no guide bearing on them.?
Freehand. I like heavy routers for stability....that's an old Makita 3612.

36 grit in the beltsander will level the high lead on the poured side.

[capt jake]

Thanks again. This is a previously finished rudder; epoxy/varnish. I can't locate any gasket material (without heading into town) but do you think that the hard backing on a note tablet will siffice? I have used this in place of gasket material in hte past.

Also, am I going to have any nasty problems with the epoxy/varnish edge while pouring? I realise that I will have to re-finish the whole thing when done.

[Bob Smalser]

Any cardboard will work.

I'd take off the varnish, first.

[capt jake]

Thanks! I guess I answered my own question. I already have it poured and it worked great! Only charred things a tiny bit when using a torch to help it flow a bit. Anyway, it is all complete and one coat of epoxy over the works. smile.gif smile.gif

PS: I copied your 'star'. It looks great. I hope the color of the Mahogany will even out again. After sanding it, the color is lighter than the rest. I will park it outside after it is all complete in an effort to even it out with the UV.

[Dave R]

Jake. Prove it! I just want to see pictures. :D

[capt jake]

I WILL post some pictures when it is all 'done'. But I have to 'upgrade' my Imagestation account to do so. :rolleyes:

[Dave R]

Jake, e-mail the photos to me. I'll post them. Or post them in Frank's gallery section.

[Cosmo Lengro]

;)

[capt jake]

And you thought I forgot???
http://www.messing-about.com/photopost/data/500/9Dsc01675-med.jpg

Thanks for the help Bob! smile.gif smile.gif

I only hope the Mahongany will darken to match the rest. I had to sand it a bit to level the lead.

[ 09-27-2005, 08:59 PM: Message edited by: capt jake ]