Pipe Rudder Sequential Construction Photos (51 pics)

[Bob Smalser]

Originally posted by boatlover:
Bob,

Parts 1 through 3 were posted before the new machine. Most, but not all, the info is in the pictures, which now show only the little red x's.

You probably don't like to chew your cabbage twice, but could you ..... ?
Too hard to fix what’s broke, so here’s the whole shebang. Download them if you want them for reference.

Gardner’s Plan from The Dory Book:

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088792.jpg

Marine brass and red brass from McMaster Carr:

http://pic3.picturetrail.com/VOL12/1104763/6490387/81122416.jpg

Layout:

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088736.jpg

Cutting, Shaping and Fitting:

http://pic3.picturetrail.com/VOL12/1104763/6490387/80883564.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/80883571.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81087815.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81087835.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088761.jpg

Continued…

[Bob Smalser]

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088777.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81276726.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81276748.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82554735.jpg

Turning, Milling and Threading with Blacksmith-Machinist Mel Ensor:

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088158.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088183.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088720.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088121.jpg

Continued…

[Bob Smalser]

Pouring Decorative Lead Weight:

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

Laminating Rudder Thwart and Tiller Yoke To Match Camber:

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088143.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82385088.jpg

Boring and Plumbing Shaft Hole:

http://pic3.picturetrail.com/VOL12/1104763/6490387/82734078.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82825179.jpg

Continued…

[Bob Smalser]

http://pic3.picturetrail.com/VOL12/1104763/6490387/82734074.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82734076.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82734071.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82734069.jpg

Installing Hull Reinforcing Block and Rudder Stock:

http://pic3.picturetrail.com/VOL12/1104763/6490387/82822056.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82822060.jpg

Determining Shaft/Rudder Stock Length and Yoke Alignment:

http://pic3.picturetrail.com/VOL12/1104763/6490387/82822052.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82822049.jpg

Continued…

[ 02-19-2005, 01:56 PM: Message edited by: Bob Smalser ]

[Bob Smalser]

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320019.jpg

Milling Shaft for Rudder Housing:

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320007.jpg

Hard Silver Brazing Rudder Housing and Shaft:

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320002.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/83319994.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/83319975.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320389.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320383.jpg

Cleanup and Fairing Joints and Flaws with Soft Solder:

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320378.jpg

Continued…

[Bob Smalser]

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320370.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320501.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/83320361.jpg

Bedding Hardware in Epoxy:

http://pic3.picturetrail.com/VOL12/1104763/6490387/84455215.jpg

Sheathing with 2 Layers of 4 oz Cloth and Finishing Woodwork:

http://pic3.picturetrail.com/VOL12/1104763/6490387/82734141.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/82554788.jpg

Boring for and Fabricating Pivot Pin:

http://pic3.picturetrail.com/VOL12/1104763/6490387/83400489.jpg

One end is threaded and the other brazed to make a perfectly-symmetrical “bolt”, and a fitted bronze bushing was installed in the rudder blade.

Yoke Hardware Fabricated and Temporarily Installed:

http://pic3.picturetrail.com/VOL12/1104763/6490387/85826519.jpg

Continued…

[ 02-19-2005, 02:00 PM: Message edited by: Bob Smalser ]

[Bob Smalser]

Rudder Assembled and Tested for Fit and Function:

http://pic3.picturetrail.com/VOL12/1104763/6490387/85796752.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/85769044.jpg

http://pic3.picturetrail.com/VOL12/1104763/6490387/85796739.jpg

Then disassembled for final touchup waiting completeion of the rest of the boat.

Nuts/shafts will be bored and bronze cotter pins installed during final assembly.

[ 02-19-2005, 02:10 PM: Message edited by: Bob Smalser ]

[StevenBauer]

Saved it! Thanks for all your efforts, Bob. I know it's extra work to document things like this and we sure do appreciate it.

Steven

[maa. melee]

Bob, I'm not a huge fan of epoxy so I'm not too sure about this but how well will that epoxy Double D-hole hold up on the tiller yoke to the torque on the shaft? Will it fracture or round out?

[Bob Smalser]

Originally posted by maa. melee:
...how well will that epoxy Double D-hole hold up on the tiller yoke to the torque on the shaft? Will it fracture or round out?The yoke bearing plate absorbs the torsional stress of turning the rudder....not the epoxy.

http://pic3.picturetrail.com/VOL12/1104763/6490387/81088720.jpg

[ 02-19-2005, 08:56 PM: Message edited by: Bob Smalser ]

[boatlover]

Bob, ... Sir,

Many thanks !

I got the file on my hard drive. (I may have to move it to the secondary HD for space considerations, but that is MY problem.)

Again, many thanks !

Regards,

Ed R

(Edited to remove a mis-statement. As I paged down to the end, some of the pictures had not yet come up, and there were some red x's. On going back to the top, and paging down again: no more red x's !)

[ 02-19-2005, 10:49 PM: Message edited by: boatlover ]

[maa. melee]

Ah I see it now Bob. Guess I was distracted by the fine job you did to notice! Nice work and thanks.

[Lion]

Bob, great post and fine work.

Thanks,
Lion.

[chergui]

Very cool. Any chance we can see her in PT in September?

[Bob Smalser]

Originally posted by chergui:
Very cool. Any chance we can see her in PT in September?We'll see.

Labor Day is when I realize I'm way behind on all I gotta get done before the November rains begin.