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Thread: A new way of running Boatyard during this present situation and beyond

  1. #36
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The centreboard is now fitted and just a few more coats of varnish and a pair of quarter knees and a rudder to make.


    Now complete with a pair of traditional oars


    The centreboard just needs to befitted with the fiction pad on the front face of the centreboard to keep it in its position when rowing or sailing


    Looking more like the Mai class dinghy that was planned for as the tender for Mai Star II



    Because it is going to be working dinghy basic fitting to be fitted to this boat, However, any of Mai Star Class will be able to be fitted with bronze fittings


  2. #37
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    Default Re: A new way of running Boatyard during this present situation and beyond

    From traditional wood boat building to modern boat construction



    Repairs to boats that major de-construction done to them. In this case rebuilding the centreboard case and strengthening up pivot point for the centreboard pin which was under spec before. The next job isto some major grinding of the inside of the hull round the centreboard slot in the boat before carefully re-building the lamination's to refit the centreboard case back in its original position and once it is in position re-enforce the sides of the centreboard from the side loading on the centreboard case.







    The long term refit of the Morgan Giles 30 which will be going out in to the yard so other boats waiting to come in the workshop can get their work done







    The cold moulded speed boat is now ready to be sprayed so it can also be removed out of the workshop and turned over and the deck and the engine can be fitted so it too can get back on the water







    We have apprenticed trained boat builders who can restore even the tidiest of classic craft back to their former glory







    We even mould our own class of classic grp dinghy





  3. #38
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    Default Re: A new way of running Boatyard during this present situation and beyond

    This week was spent ordering wood for the ribs and frames for Mai Star II. These days trying to get good quality green oak at a reasonable price in difficult as many of the timber merchants are no longer around. Also to many tree surgery people cut the logs into small unusable sizes for boat building.

    I do have enough nails to re-nail the ribs however, I may have to buy a number of long nails to go through the frames and some very long nails to go through both the frames and the beam shelf.

    Because of the very hot weather it is impossible to work out in the sun for long without needing to get undercover. So I am not doing any work on the boat until the temperature drops a lot and makes working out on the boat bearable. So its back to the workshop and making different plans for other work on the yacht restoration. May be cut some wood to make some of the deck beams that need replacing.


  4. #39
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Yesterday, while waiting for some epoxy to cure off, I had a good look at the sheer strake of the yacht and it was not good at all. The whole of the sheer strake will have to be replaced as one length from the stern on the starboard side is got rot in it along the upper part of the plank and the other three pieces which may up the forward part on the starboard side and the whole of the port side as been used in the past to nail the deck down to with iron nails which have rotted away and left holes and splits in the upper parts of the sheer strake. So in order to make good the sheer strake to fix the new deck down on to it is best to remove and replace whole all and start again. The fill in pieces which were nailed again to the beam shelf will have to replaced as well as they to were iron nailed down into the beam shelf and their nails have rusted away as well. So as well as replacing the deck beams and carlins for the cabin, the ribs and broken or rotten frames the top planks are now going to be replaced. So at the moment the list of parts coming off and getting replaced is getting ever longer. It will stop soon as we get to the bottom of the major parts that need replacing. The rest of the hull is in good condition if in need of a bit of primer to protect it while the work is done on it.

  5. #40
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The other day , while waiting for some epoxy to cure off, I had a good look at the sheer strake of the yacht and it was not good at all. The whole of the sheer strake will have to be replaced as one length from the stern on the starboard side is got rot in it along the upper part of the plank and the other three pieces which may up the forward part on the starboard side and the whole of the port side as been used in the past to nail the deck down to with iron nails which have rotted away and left holes and splits in the upper parts of the sheer strake. So in order to make good the sheer strake to fix the new deck down on to it is best to remove and replace whole all and start again. The fill in pieces which were nailed again to the beam shelf will have to replaced as well as they to were iron nailed down into the beam shelf and their nails have rusted away as well. So as well as replacing the deck beams and carlins for the cabin, the ribs and broken or rotten frames the top planks are now going to be replaced. So at the moment the list of parts coming off and getting replaced is getting ever longer. It will stop soon as we get to the bottom of the major parts that need replacing. The rest of the hull is in good condition if in need of a bit of primer to protect it while the work is done on it. The port side appears to be the side that as had the worse damage over the years with most of the broken ribs that have been replaced and the new broken ribs that now have to be renewed this time round.The other major job over the next few weeks is going to be taking out the old interior bulkheads and bunk fronts and lockers so the inside can be got at with no things in the way and making it easier to repair and replace all the parts needed to be renewed and new items put in position when the yacht is refitted.

  6. #41
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Because of the extremely hot weather of the last week, I was not able to any major work as the jobs that were to be done this week were either in the main workshop is like an oven at the moment or outside in the temporary workshop which is like an oven in this weather as well.
    I hope to get another temporary workshop frame for Mai Star II as well, so that too can get put under cover now and for the winter when the weather gets a lot cooler. In the meantime, it is a good time to get on with sorting out working practices to make them more effective and cut waste to a minimum wherever possible.
    One major job that will need tackling will be a major stock take of the workshop and the yard to see what is laying around and what needs attention to get turned into a cash flow for the business post Covid 19. Starting work on a new office,toilet and break area for anyone coming to the boatyard and workshop. Then an outside wood and plywood store to help free up space in the workshop which at the moment can not be used.

  7. #42
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    Default Re: A new way of running Boatyard during this present situation and beyond

    I am busy working and giving advice to owners of a number of different early generation hardy boats ranging from the small Hardy Navigators , Hardy Pilots and a number of other of the Hardy range including Hardy 25's. Simon also worked on the other boats build by hardy Marine, they include the MS 18 and MS 21 motorsailers, the fishing 17, 20, 24 and the Fishing 33. Simon also worked on the Seawings range as well while working for Hardy Marine. They all have different jobs and advice to be given to the owners and in some case work for my company to do on them. Some there are small jobs and other work as involved complete refits and others just needing a new rope fender replacing and a number of small and medium jobs in between. So over the next few months there are going to be a number repairs to be done a couple of Hardy Boats close to my workshop.
    So of the early generation of Hardy Marine Simon worked on all the boats so he as a vast knowledge base on which to help any owner which to work on their boat or send it to Simon to work on their boat.

  8. #43
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The hull now all ground back to get it ready to start to fibreglass it back into position


    Now that it is ground back the first thing to do is put spacers in the centreboard case slot to keep the edges in position while glassing up the joint.


    Now the centreboard case is in position, it as to be braced from both sides to ensure it is up right and centred in position

    Once it is in the correct position, then it time to make up two sets of braces either side of the pivot point to take the stress through the boat at this point.

    Once the centreboard case is in position the deck beams can be positioned to be over the raised part of the centreboard case to take the stresses from the top of the centreboard when the yacht is sailing

  9. #44
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The Cornish Crabber's centreboard case finally getting glassed back into position in the bottom of the boat. Just many layers of interwoven roving mat and CSM to be glassed in to build the layers back to the original specification and then a few more to be on the safe side. The fitting of the spacers inside the centreboard case was done with the help of a friend and former apprentice of mine. He is the person who has started the ball rolling so that on Monday I can start to build up the layers of fibreglass until there are enough layers to the fit the two pairs of triangular webs to brace the forward end of the centreboard case with the pivot is located.

  10. #45
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The Cornish Crabber's centreboard case finally getting glassed back into position in the bottom of the boat. Just many layers of interwoven roving mat and CSM to be glassed in to build the layers back to the original specification and then a few more to be on the safe side.





    The fitting of the spacers inside the centreboard case was done with the help of a friend and former apprentice of mine.




    He is the person who has started the ball rolling so that on Monday I can start to build up the layers of fibreglass until there are enough layers to the fit the two pairs of triangular webs to brace the forward end of the centreboard case with the pivot is located

    .



  11. #46
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Now the centreboard case is tacked in position with a single layer of 2oz CSM. It will now have layers of CSM followed by interwoven roving until the original amount of layup is achieved and then it will be re-enforced with a a pair of marine plywood webs glassed on to the centreboard case and glassed on to the bottom of the bottom to take any stress loading on the centreboard





    The framework tent is stating to go up around Mai Star II, The good part of this framework is that you can shorten it or make it any length you like, for Mai Star II we can leave out one of the sections as it will belong enough without fitting the last section.




    Once the tent cover is put over then I will be able to put lights under the cover to make it possible to work on it over the short winter days and long nights

  12. #47
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The framework tent is going together slowly but surely and it will be getting it covered shortly


    The framework now finished and the cover put over the boat so that work can begin to get the cabin sides and front off the carlins and in the workshop to be sorted an jigged up ready to put back on the boat when all the deck beams and side deck beams and carlins are remade and the cabin can be fitted on a stable deck structure




    Now that the cover is in place it is time to get the area under the boat clear of any rubbish that will stop from being able to get to any of the under water parts of the hull where it is a needed to get to remove and replace any fittings



    The cover is a close fit to the boat, however, there is enough space around the boat to get to the necessary parts to come off and replace them when it is time to do it.





    The ~Cornish Crabberis coming along reasonably well with the centreboard case glassing in coming along with a steady build up of layers of fibreglass to re-instate the case once more.



  13. #48
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    Default Re: A new way of running Boatyard during this present situation and beyond

    A photo of the three people who started J-Star Marine Services 40 years ago this week



    The present workshop and yard from which business work from in Essex

    When we are not in the workshop or in the yard we are out on the road serving of clients in other parts of the country





    We build classic GRP dinghies from modern materials from sources close to the yard where possible. All the timber comes from FSC forests and from other fixtures and fittings are sourced locally where possible to reduce the business's carbon footprint as low as possible.

    We repair and maintain classic as well as modern boats, A Enterprise dinghy which this year celebrates its 60th year and a modern Hardy Navigator


    We build traditional clinker build dinghies to order


    We either maintain motor launches and larger motorboats for many clients around the local area.

  14. #49
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    Default Re: A new way of running Boatyard during this present situation and beyond

    40 years today J-Star boat Services opened bring its unique family boating values to the marine industry. All the staff are yachtsman with a personal insight to how boats work and what don't work. This way they can give you the best advice on any updates to your vessels be they small or large. We have the experience that counts.


    The latest generation working along side his father, learning the skills his father over 40 years ago as an apprentice boat builder himself



  15. #50
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Thatís beaut, Simon!
    http://fairmaid.blogspot.com.au/

    "It's dawning on me that I should have worked out the tumbler details more in advance, rather than rely on bluster and over confidence. But that's just silly." Jim Ledger.

  16. #51
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Having sourced a supplier for my green oak and larch it was a matter of having to pick it up from the timber yard the only problem was it was in another part of the UK, 200 miles away from my yard.



    although there are knots in the first piece the patterns for the frames use the grain pattern to let the grain go in the direction of the curve of the frame



    The other plank as a lot straighter grain and it is good for making ribs,which so far are about ten ribs down the port side. There are sure to be more as we go along.However this plank will make a good start in making new ribs



    An use for a speed boat trailer, a good timber carrying trailer as well.

  17. #52
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The original carlins are past their usable life and are being removed to make way for new carlins and beams that will be fitted in much the same way as the original parts. The only difference being that the tie rods will be made out of a nonferrous material



    The carlins beams position were all measured before they were removed so we know where they all go, so when rebuilding the deck structure they will all go back in the same position
    Both ends of the short beams that are fitted to the beam shelf are fitted with a half dovetail joint which is the way they are going to be refitted

    The wood on top of the beam shelf is all going to be replaced with new hardwood so that the deck beams and deck will have a good sized area to get fixed to when it time to relay the deck
    The forward part of the deck is good condition just needs to be faired up after the new top strakes are made and fitted



  18. #53
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The centreboard case is now glassed in position with the same amount of fibreglass and then more as been added to strengthen the joint.





    The lay up is over the original to ensure it now part of hull once more



    The webs are going to be placed in position either side of the re enforced area of the centreboard case to make it more ridged and to make it possible to take the loading over a larger area







    The next job is to make a post to stand up the front face of the centreboard case to support the mast and to attach the centreplate lifting gear to as well

    Last edited by jstarboats; 09-16-2020 at 10:05 AM.

  19. #54
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Now that the carlins are removed as well as the wood on top of the beam shelf,it can be seen how much work is going to be needed to sort this area of the deck beam structure.





    Apart from the old iron fixings there appears to not be much wrong with the beam shelf that a small piece of grading will not put right




    This is the only small area that is in need of repairing








    The top of the transom looks like it is going to need renewing as it is in a poor condition on the starboard side, so before any work is done on the deck. It is going to have some major work done to the transom



  20. #55
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    Default Re: A new way of running Boatyard during this present situation and beyond

    New project boat just come into the yard for conversion from a pulling boat to a small motor launch







    It was full of the last owner equipment which will be got rid of over the course of time, much of it will be recycled or used in some way, however, not put in landfill




    The builder plate, showing it was build in 1995



    The old equipment now removed and put in storage and now a plan of action to be set out to remove some items from the inside and what needs to be put in position to fit the engine beds and stern tube and make a new rudder and skeg and propeller guard



    let the fun begin now the boat is empty of the old equipment and a blank canvas is before us to convert the boat.





  21. #56
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The iroko planned to thickness and then cut in half and the grain reversed against each other and then glued together




    Then joint glued with epoxy glue and plenty of cramps



    Once the glue is cured a quick run through the planner and then radius the corners and fit the base on to the hull and bedded on with profile filler and the whole post will be glassed on to the front of the centreboard case



  22. #57
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    Default Re: A new way of running Boatyard during this present situation and beyond

    On the first day in the yard it was emptying out all the loose equipment and floorboards





    The next morning it was the turn of the floor bearers and the forward and aft thwarts which are not going back in after the boat becomes a motor launch

    The next job was to remove the rowlock blocks and sort out the way to get to the rudder fittings which will have to be changed to a different design to hold a new designed rudder




  23. #58
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Just setting up the post to take a few measurements, before fitting to the bottom so that it fit against the centreboard case.



    Lining post up so that it is the same amount out both sides and that it is vertical and it inline with the centreboard case and the deck beams when they are fitted in position





    The job of getting it fitted along the floor and the centreboard case is going to be interesting, as soon as this is done it will be glassed into the bottom of the hull and on to the front of the centreboard case.


  24. #59
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    Default Re: A new way of running Boatyard during this present situation and beyond

    I am going to quiet for a couple or three weeks on the forum, as I have burned myself out keeping my business going through this Covid situation and I now need a break from my business to clear my mind and have a change in scenery. The pressure I have been under as been great as without any government grants being available to me. I have had limited cash flow and a couple of clients who have not paid me for sometime. So in order to keep going over the next few months I have closed the business in the short term and reevaluate whether my business. It is going to take sometime to think this through, however, in the present situation, it is what I have to do for the good of my family and myself.

  25. #60
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Thank you and stay well. Have fun too.

  26. #61
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Sorry to hear that, Simon. All the best with whatever decisions you make.
    http://fairmaid.blogspot.com.au/

    "It's dawning on me that I should have worked out the tumbler details more in advance, rather than rely on bluster and over confidence. But that's just silly." Jim Ledger.

  27. #62
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Hi Folks

    Back at work again with more of a spring in my step and a clear vision for the future, Just got to get the work in the workshop and around the done and get back on my feet in the cash flow skates.

  28. #63
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Good! and Good Luck!

  29. #64
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    Default Re: A new way of running Boatyard during this present situation and beyond

    One thing that the last couple of weeks away from the boatyard and workshop as taught me, is that you need to de-clutter not only your mind, but your place of work. That is why over the next couple of weeks I am going to go over the yard and the workshop and sending to the local scrap yard any of the metal laying round the yard and in the workshop and any other metal that go there. Also put up for sale all the surplus equipment I have build up over the years that are no long needed or used. Once that is done then the workshop and yard will look better and I will have a better mindset for the future. As the old saying goes a clean yard and workshop makes for a better working space and helps with keeping a positive mindset as well.

    Also it will give me a chance to see what boats and projects need to go and make room for more work to come into the yard over the winter and into the spring months next year.

  30. #65
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    Default Re: A new way of running Boatyard during this present situation and beyond

    All the floor bearers in the rowing boat were removed because they were not fixed down enough to take the loading that they are going to have put through them when they are going to be used as part of the bracing for the hull when the engine beds are made and fixed to them to make up a matrix for the hull.




    The first job is to remove all the old fibreglass matting and the old paint and let them dry out so when they go back in the boat they can be glassed into the hull
    so that they are bonded to the hull correctly



    They have a lot of old material fixed to them sealant and fibreglass and resin and a lot of paint

    Now all the paint is removed it is time to sands them down back to bare wood and let the air get to the wood so it can now dry out




    All sanded and now just got to let them dry out and then put to one side while the rest of the boat gets worked on. The next job on the boat is to remove the rest of the old paint off the gunwales and the thwarts and aft seat and then set the boat up on a build stock to get the boat level and square before get the hole bored for the stern tube.


  31. #66
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    Default Re: A new way of running Boatyard during this present situation and beyond

    I have now made a start on getting to grips on how the inner and outer parts of the keel are fixed together. Now having removed the inner keel or sometimes been called a hog, it appears that the two halves are screwed together with some large and long bronze screws. This being the case once the screws from the inside are removed the outer keel should come away from the hull. I can but hope this is what is going to happen. However, I have my doubts that it will be that easy. boats being boats it is never that straightforward.
    More likely to need some gentle persuading to come apart. In other words a big hammer in the right place with the odd wedge to help it on its way. Once that is off then the major work on the can begin. However, before that can happen I have to make room in the workshop, so that it is under cover and able to dry out the hull and heat the workshop to do the fibreglassing on the new stern tube and reinstall the floor bearers.

  32. #67
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    Default Re: A new way of running Boatyard during this present situation and beyond

    The inner keel or hog as it is sometimes called has been removed so that the outer keel can be removed so the the shaft log can be fitted and the new outer keel can be made and also the inner keel can be remade and fitted.




    The aft end of the hog is going to be the largest challenge as it as the larger screws through the hull and also they are badly corroded and will very likely break
    off while trying to remove them.


    The extra rowing position panels which made up part of the gunwale capping as been removed in four positions as they are no longer needed or wanted and the gunwale capping is re-profiled to match the rest of the gunwale capping.





    The gunwale capping now re-profiled and the gunwale capping getting its first sanding to get rid of the old paint that was covering the gunwale capping.




    The start of the sanding of the gunwale capping just the next 20 plus feet to go
    .



  33. #68
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    Default Re: A new way of running Boatyard during this present situation and beyond

    Having been away from the project for a while I thought I would bring you up to speed.


    The centreboard is now all glassed in position and with more re-enforcement than before to ensure the re-installed centreboard case does not every come away. The centreboard case will have re-enforcement knees glassed either side of the pivot point to give the area added strength and support.


    However, before they are fitted the lower part of the mast support post is getting fitted to the forward face of the centreboard case.


    The support post is first being bonded to the hull at the bottom and along the aft face with epoxy resin/glue which as been thickened with mixture of epoxy filler powders so that the resin/glue mixture can take up any minor void and make a strong bond between the faces.

    The support post is being held in position a pair of clamps while the epoxy resin/glue cures over the next few days and then the epoxy resin/glue will be sanded back and then a series of epoxy fillet will be profiled into the area at the front of the centreboard case and at the bottom of the post so that the fibreglass will be able to follow the curves and lay flat without ant air pockets in the layup as it goes around the many curves.


    Once the support post is all fibreglassed into position the top of the post will be cut to is final height and the stainless steel upper part of the support post which will take the mast pressure coming down through the deck via the deck beams and also the lifting tackle that is going to be fitted to the support post as well.
    Once the mast support post is glassed into position then, it will be time to turn our attention to to support knees on the two sides of the centreboard case and fitting the deck beams and making the upper support post to be fitted to the lower part of the support post
    .





  34. #69
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    Default Re: A new way of running Boatyard during this present situation and beyond

    On the motor launch conversion project front, I have now taken out the aft seat, which in the end did not take much to remove apart from a few hidden screws put into the seat top which were put in from the outside and then covered with filler and paint. With this seat out it is now much easier to get to the last fixings holding the outer keel in position. The outer keel as to come off so that the stern tube can be fitted and a new profiled keel can be fitted ahead of the stern tube. Also at the moment the rudder fittings on the transom as to be removed and redesigned to hold a new shaped rudder.

    At the moment I am grinding back the inside of all the old paint and fibreglass matting which was there from when the floor bearers were last fibreglassed into the hull. This time the floor bearers will be glassed in in a very different way and will also have a set of engine beds glassed in the hull. The extra fibreglassing will strengthen the hull and make it a lot stiffer.

    So for now it is more power to the grinder and get the inside all ground back to clean fibreglass and then the fun can start of rebuilding the inside of the boat.

  35. #70
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    Default Re: A new way of running Boatyard during this present situation and beyond

    When as a company I am faced with a problem, I think why not build a dinghy or two as there will always be a market for a well turned out dinghy.
    So as England go into the second lockdown, I have decided that at J-Star Marine Services I will be going into making our popular 8 ft general purpose dinghy. Coming in a number of different wood trim levels & also deck fitting levels from galvanized fittings or the bronze fittings . I am sure they will sell when the lockdown is over as people will wish to get out on the water once again.

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