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Thread: The second restoration of Mai-Star II

  1. #211
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    Default Re: The second restoration of Mai-Star II

    ^ That is a real pita when you consider all of the other work you have put into her.
    It really is quite difficult to build an ugly wooden boat.

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  2. #212
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    Default Re: The second restoration of Mai-Star II

    It is a pity, but carp happens and you over it and you need to find out how it got that way.

    Regards

    J-Star

  3. #213
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    Default Re: The second restoration of Mai-Star II

    Major problem found and this is going to need the mast removing from the yacht to sort out

    Old age as finally caught up with the old lady, the deck beam and carlin have given out

    The front end of the carlin as broken and so the side deck will have to come up

    Half the deck up the rest will be done in the morning and then the repairs can start

    The long job of removing all the fixings on the toe rails and rubbing skates

    Just a few more fixings to go.

  4. #214
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    Default Re: The second restoration of Mai-Star II

    Putting the old hatch on to a jig to set it up to make the new hatch fit within the size of the old hatch



    The new fore hatch will still have many of the old features, however, a few may be modify to fit into the new design of the new fore hatch







    Getting the new fore hatch pieces planned and thickness-ed up ready to set them up to make the corner joints







    Which will be unlike the last joints which were just screw together as butt joints.





  5. #215
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    Default Re: The second restoration of Mai-Star II

    Marking out the areas between the deck beams so not to cut them while removing the deck

    More marking out

    One major bit to remove from the fore deck,so to gain access to the two damaged deck beams below

    Steel knee put in sometime in the past to connect the deck beams to the grown frames

    This is the port side deck to hull steel knee before the deck is removed

    Most of the foredeck is off now, just a small area beside the forehatch area to the cabin front left to remove.



  6. #216
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    Default Re: The second restoration of Mai-Star II

    An excellent time to paint the fore-cabin I replaced the deck, didn't paint the fore-cabin Primed the underside of the deck though

  7. #217
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    Default Re: The second restoration of Mai-Star II

    Hi tillergirl,

    It is going to be a good time to paint it and do a few small jobs that I have been putting off for a while. At least with the deck off you have better light to work with a do the bit you miss the last time you did it with the deck on. The deck is going to be primed again before it goes back on and it will possibly get finished painting before the deck is relaid down. It will save a lot back twisting , paint on your back in small areas like the fore peak.

    Regards

    J-Star Boat

  8. #218
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    Default Re: The second restoration of Mai-Star II

    Absolutely: it is possible though:

    [URL=http://s217.photobucket.com/user/rgaspar_album/media/P1010320.jpg.html]

    Back twisting, painting on your back, drips on your face, paint on the overalls and the odd 'donk' on the head.

    Evidence of vast experience:

    [URL=http://s217.photobucket.com/user/rgaspar_album/media/Fitting%20Out%20last%20week%202011%20011_1.jpg.htm l]

  9. #219
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    Default Re: The second restoration of Mai-Star II

    Hi Tillergirl,

    After almost forty years you think I would know better than to keep doing to myself. But it is like the call of the sea, it keep pulling back to do the same thing over and over again.

    Regards
    J-Star Boat

  10. #220
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    Default Re: The second restoration of Mai-Star II

    Marking out fore hatch ready to cut joints



    Starting to make new toe rails to replace the old damaged toe rails on Mai-Star II







    Here is one of the old toe rails using it as a pattern for the o

    new toe rails







    Getting on with the varnishing of the rubbing skates and new toe rails and painting chain locker bulkhead and the step locker lid







    All the cabin floorboards painted now ready to go back in the yacht when the rest of the work in the cabin is finished







    Rubbing skates and toe rails get more coats of thinned varnish building up the layers slowly







  11. #221
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    Default Re: The second restoration of Mai-Star II

    The step locker getting ready to be painted







    Step locker now painted with a fresh coat of undercoat





  12. #222
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    Default Re: The second restoration of Mai-Star II

    Getting back to work on the hull of Mai-Star II, starting to build up the coats of undercoat, The first of four coats of undercoat.



    Now the first coat of undercoat is on, now the filling and fairing can being with sanding and filling until we get a fair hull again.







    Starting to look more like her old self with a beautiful white hull.





  13. #223
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    Default Re: The second restoration of Mai-Star II

    Marked out the mortise and tenon joints and made and start on cutting them



    Cut all the tenon joints and now setting out the base on the bench ready to mark out the mortises







    Let the fun begin cutting the mortises by hand.





  14. #224
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    Default Re: The second restoration of Mai-Star II

    Hello Simon,

    it`s good to see you makeing progress inspite of the deck setback, Mai-Star II is lucky to be in your capable hands!!
    How is the Enterprise getting on? did you manage to get any sailing in this year?

    Greetings from very Novembery Germany,

    Alan.

  15. #225
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    Default Re: The second restoration of Mai-Star II

    Hi Alan,
    I am getting my apprentice to make the new forehatch as part of his apprenticeship projects, so he can show the tutor how far he has come on since he started with me just over a year ago. As for the Enterprise, I did not get the time to get out on her this year due to work commitments. Will hope to get out on her next year.

    Regards
    Simon

  16. #226
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    Default Re: The second restoration of Mai-Star II

    Now back to work on Mai-Star II with an inspection of the hull to see what is needed to be done first



    The hull is in reasonable condition just will need a good sanding before the painting can continue over the next few months







    The bottom looks in good condition apart from a few gaps where the planks have dried out over the summer months.







    The gaps in the planks will swell up with the winter damp condition and a little help from a hose pipe spraying water over the planks on the inside







    The new forehatch being glued together, then it will be ready for the next stage cutting the rebate around the top to fit the upper section of the hatch.




    Last edited by jstarboats; 11-17-2016 at 12:21 PM.

  17. #227
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    Default Re: The second restoration of Mai-Star II

    The fore hatch is coming along well with the surplus glue removed and the top and bottom faces of the hatch planed and sanded, just got to sort out the router and its cutter to cut the rebate on the top edge of the hatch to then be able to make the upper part of the hatch and the top of the hatch to be made out of deck planks and a skylight fitted to the centre of the hatch to let sun light into the forward end of the yacht.

  18. #228
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    Default Re: The second restoration of Mai-Star II

    One job to sort out the top of the transom that is going lots of fun




    Sort out the coamings around the cockpit sides




    Make a gas bottle locker to keep the gas bottle from moving round the cockpit while at sea



    The broken deck beam that needs replacing before the new deck can go back on a job with top priority




    The mast step that needed replacing at the same time as the deck beams


    A new rib needed to be made and steamed into place as one of the jobs over the winter


    A lot of painting and varnishing to be done over the winter months as well both on the inside and outside.


  19. #229
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    Default Re: The second restoration of Mai-Star II

    How time flies when you get busy on other projects when you can a boat builder. You ever seen to find time to get on with your own projects, namely refitting your own yacht and get her back in the water and go for a sail yourself to ewlax at the end of a long day or week. However, having got to the end of a couple of long term projects it is a good time to make a start on my own yacht again. The first job is to get the two broken deck beams out and repair the gunwales and carlins. So then I can get them back in and get the fore deck back on and make a start on sorting out the rest of the work on the yacht.

  20. #230
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    Default Re: The second restoration of Mai-Star II

    Hi Folks,
    Now things at the Workshop have settled down a bit, I should have time to get back to repairing Mai-Star II. Getting the deck beams out and back to the workshop so I can laminate up two new beams as the old beams were not designed to take a deck stepped mast which the yacht originally had. Although there was a mast post put in place of the missing section of mast this did not stop the beam from breaking when lowering the mast in its Tabernacle . So the new new beams are going to be wider and a bit deeper to take the extra stress on the beams when in future the mast as to at any point have to be lowered in this fashion.

    Another job I am going to get one of my apprentices to do is to finish off the new fore hatch and help lay the new foredeck over the coming weeks. So all being well should be able to get Mai-Star II back in the water for the autumn and have some winter sailing on her.

  21. #231
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    Default Re: The second restoration of Mai-Star II

    Mai-Star II with its cover off and the spars removed ready to get transported to the boatyard so that the work on the deck can get underway before the winter sets in.





  22. #232
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    Default Re: The second restoration of Mai-Star II

    The wheels are now in motion to get Mai-Star II to my yard where I can and will be able to work on her over the winter, in between working on client's boats. Times while waiting for paint and glue dry and fibreglass work to go cure. So no down time between jobs. The first job to do is toi build a shelter over the boat to keep the weather off the deck and cabin sides. So that these jobs can be tackled while the weather is against us. So as soon as the Yacht is over at the workshop the yacht will be set up in a cradle which will hold the yacht for the time it is at the workshop.

    Once covered up and set up in position the major work on the foredeck and the other deck beam work can start and then get the foredeck area weatherv tight again. Then get on with the rest of the work to get Mai-Star II ready to be recommissioned and back in the water. So over the next few weks and months we should be giving regular updates on othe progress of the work until we get her back in the water and sailiong again.

  23. #233
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    Default Re: The second restoration of Mai-Star II

    Good to hear it, and I will be checking for updates.

  24. #234
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    Default Re: The second restoration of Mai-Star II

    The area in the yard cleared ready for her arrival at the yard

    Peter Down's Boat Transport picked the yacht up this morning from Fox's Marina Ipswich and were at the yard in good time.


    Peter and his son were soon on the case and unloaded in a quick time and the yacht was soon set upo in its new home and ready to be worked on over the next few months









    All safe and sound and ready for a cradle to be made over the next week ready for the team to get on with her refit.





  25. #235
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    Default Re: The second restoration of Mai-Star II

    Now the hard wook can start in earnest. First job is to build a mobile shed/cover over the yacht to help the weather off the decks while we remove the deck beams and part of the gunwale and a section of carlin from the starboard at the foreward end where the corner of the cabin and the deck meet and that as always been a problem. So I will have to look into a way to make this joint as watertight as possible and stop the problem from coming back and undoing all the hard wook. One job that will have to be sorted will be the deck beams where they have dropped over the years, to the point where the centre of the deck as dropped so that there are points where the deck holds water and does not run off like it should do if the deck beams were in their correct position.

    Another job for the coming week is to undress the mast and put the rigging away in storage and put the mast up in the roof of the workshop so that it will be kept safe and out of the way of other projects.

    Over the next few months it is going to be busy down at the workshop and around the yard sorting out things and getting the yard and workshop the way I wish it to be and set out to make best possible use of the space.

    So there going to be fun and not so much days and months ahead.

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