Posts in Category: Engine, hull & laying the deck 2011 – 2015

Winter projects 2015/16: rigging, gaff and blocks

Serving the standing rigging

  • Serving the standing rigging
  • Lanolin for serving the standing rigging
  • New deadeyes for the standing rigging
  • Standing rigging all ready for 2016
  • Stitching leather to the standing rigging
  • Serving board for the standing rigging

12 October, 2015 finds us back in Derbyshire and a sense of being ‘in limbo’ sets in after so long away. What are we going to do? There’s little interest in the house in Matlock Bath, and as we scour for sale listings in Suffolk and Derbyshire, we realise there probably isn’t a better place to live, after all. Following a ski trip to Val Thorens in late January, the decision is made . . . pay off the Estate Agent, take the house off the market and plan some serious ‘home improvements’!

The workshop at the top of the garden becomes a hive of activity again over the winter months, with the smell of tallow, varnish and leather, often brought back into the kitchen when it becomes too cold or damp outside. Steve turns his mind to the standing rigging . . . shrouds, backstays, forestays and new dead-eyes are all complete, re-served and ready for the launch day.

Making the parrel beads: tree to sea

We take a short break for a trip to Holland at the end of February 2016, meeting up with the Dutch OGA for a weekend of baking bread and learning to splice ropes. Inspired by both bread-making and ropework, it’s back to Derbyshire. After seizing in the new thimbles the blocks, made nearly ten years ago when the project didn't seem to be quite so big, are ready for use. Steve experiments with the lathe for a new set of parrel beads. Made from some ash felled in our own garden, he’s really pleased with his example of ‘tree to sea’, as they fit neatly onto the gaff.

  • Ash tree from the garden
  • Ash, first cut, for parrel beads
  • Ash, trimmed, ready for the lathe
  • Ash on the lathe, making the parrel beads
  • Parrel beads ready for cutting
  • Set of parrel beads, fresh off the lathe
  • New parrel beads, tree to sea
  • Remains of the old gaff, ready for a new one!
  • Making the new gaff jaws at the top shed
  • Varnishing in the sitting room - too cold outside!
  • Back outside now the varnish is dry
  • New gaff, ready for return to Suffolk
  • Set of new blocks, made from ash, and re-varnished rudder stock cover

New gaff jaws!

Next it’s the gaff spar. The jaws are completely shattered, so new ones are carefully crafted from oak during a sunny spell in mid-March. It then turns too cold and wet to varnish outside, so, leathered and gaff is fixed to the spar, it’s brought in through the sitting room window and just fits the length of the room for several coats of varnish. Taken outside again, it's awaiting transport back down to Suffolk along with another of the ‘bits and pieces’, the refurbished cover for the rudder stock, gleaming with new varnish and polish.

Finally, we’re laying the deck!

The first week in August finds us back in Derbyshire for a few days, the house is still there and judging by the state of the garden, it’s been raining a lot! Return to Suffolk on the 10th with the intention of staying for the rest of the summer. We plan to do some house-hunting, following early research by Bev on her new road bike. Beverley takes a week out to join James on 'Kestrel' in the August Classics, 14 - 23 this year while Steve is persuaded by Wendy that he must forgo sailing this summer and get on with the deck. Did he really promise that 'Cachalot' will ready for the August Classics, 2016? He gets started in earnest, making good progress by the end of the Cruise. But where's the summer gone? There's rain, rain, wind and more rain in the week up to the Bank Holiday, with a welcome invitation to dinner at the Masters on Bank Holiday Monday.
  • Cutting the first board for the deck
  • Preparing the underside
  • Preparing the board, edges and underside
  • Painting the underside
  • Underside painted and ready to lay
  • Bulkheads
  • Side decks on
  • Making a start with laying the deck
  • Underside of the foredeck painted
  • Aft deck
  • Glassed deck ready for winter 2015/16
  • Bulkheads making the interior look good
Bev drives to Matlock for a couple of days to check out the house and visit her Mum. She gets a slow puncture in the car, which becomes a theme for the week with four on the bike back in Suffolk! It's a new tyre for the car and a tougher one for the bike after four inner tubes get holed! While Bev pedals round looking for houses, Steve continues to make great progress with the deck boards and bulkheads, all grooved and painted ready for fixing. After another short trip back to Derbyshire, we put the house on the market and return for Maldon Town Regatta on 19 September. Autumn looks set fair for us to keep working on the deck into October, so we order 20 metres of glass with two-pack epoxy and put a thermometer on the coachroof to monitor temperature in preparation for glassing the deck.
We join Simon and Julia for the Cycle Show at the NEC, and try out bikes way out of our price range! The final week of September finds Steve completing the preparation of the deck, and with bulkheads installed, we're ready for our lesson from James, kitted out in our very fetching protective clothing. Everything has been carefully masked off, materials and tools all readily available, scaffold planks alongside the hull for fairly easy access and plans on how to glass the deck without getting ourselves into too many sticky corners! Bev is assigned as glue mixer, which is OK at first, but once there's only the two of us it becomes much more stressful . . . after four sessions, the job is done!

Painting the interior and preparing for the deck, at last!

Gales, trains and paint

After being forced back to Derbyshire by gales at the beginning of May, we set off for sunnier climes in Italy. Travelling by train via Derby, London, Paris and Milan then to Siracusa, Sicily (with the train boarding the boat to cross the Strait of Messina), we returned by overnight ferry from Palermo to Naples, flying back to Gatwick after a few days sightseeing in Rome.
Progress having been seriously delayed this year, Steve spent just over a week in Woodbridge in early June, achieving his Springtime goal of getting the whole of the hull interior painted at last! ‘Henry’, the hardy and generally trusted vacuum cleaner, did need the smile wiping from his face when he fell from a deck beam knocking a tin of (very expensive) paint into the bilges! With grey bilges and white above the sole, she’s looking good, and another step towards putting on the deck.

No more distractions!

Mid-June found us back in Derbyshire for the Eroica Britannia at Bakewell Showground. Much colder than last year, the weather didn’t dampen our spirits as Beverley joined Steve and Rob for a most enjoyable (and challenging) 55 miles up hill and down dale along with 3,000 ‘heroic’ riders on classic pre-1987 bicycles.
4 July and it’s off to Suffolk again, taking the Bongo and the car for the ‘long haul’, with no distractions until August! The tent's become somewhat untidy, leading to some ‘home improvements’, clearing out old wood that ‘might come in handy’ as patterns and extending the workbench to full-width of the tent: total cost, one bag of nails at £2.49!

. . . and now for the deck!

After more discussions, sucking of teeth and research into the definitive plan for the deck, it’s decided: marine ply and glass, painted to provide the look of canvas. Now the decision's made, Steve's fairing the deck beams and finishing jobs it’s easier to do without the deck on, and ordering the ply, of course. Water and fuel tanks are thoroughly cleaned, and securely installed along with a new fuel filter.
22 July: ten boards of plywood arrive on a large lorry from Lathams. After stacking it safely, we depart for Yarmouth, Isle of Wight for the weekend to say 'bon voyage' to the OGA fleet sailing to St Malo. On our return, we find Marion and Ian are stormbound on 'Eleanor' in Ipswich, they cycled round to see the boat and invited us back for supper. Yesterday, Trevor, Peter and Paul were in the Tidemill on 'Gromit', so we all repaired to The Anchor for an evening meal.

Winter project 2014/15: cabin sole and engine box

Delays on going to Woodbridge

Our trusty Bongo, due for it's MOT in May, has to have more welding done in order to pass. This means another late start to work in Woodbridge, but there's been great progress in the Derbyshire hilltop workshop!
Steve's been working on the cockpit floor, engine box and cabin sole, using the reclaimed teak from the deck.

  • Rust on the sills, failed MOT
  • All the interior stripped for the welding
  • Shiny and new again, with MOT!
  • Old cabin sole, teak and holly
  • Making the pattern for the new sole
  • New sole taking shape
  • Teak and 'holly' for new sole

Winter 2014/2015

With all the patterns carefully made before leaving Woodbridge, and brought home to Derbyshire, the winter project was to make the engine box and sole.
After a few experiments with the teak reclaimed from the deck, and various options for 'holly', the final decision was made and Steve started work in earnest.
Many chilly hours spent in the workshop resulted in a wonderful varnished engine box becoming part of the living room furniture in February, and by Easter, the sole was complete as well!

May Day weekend, 2015

May Day weekend finds us in Woodbridge at last! There's an OGA Rally at Tollesbury, so we drop off all the floors at the tent and drive on to Tollesbury. Sunday finds us back at the tent and the moment of truth. Will the floors fit? Steve lifted them all into the boat, and assembled them . . . yes! There's a few minor alterations, but it's time to start painting the interior of the hull and checking out all those last butt blocks first. The cockpit floors are also in place now. We'd hoped to spend at least a week to catch up on lost time, but the weather turns against us again. On Monday evening there's 45 mph gusts forecast for Tuesday afternoon, continuing into Wednesday, with heavy rain . . . so it's time to put the tarps up again inside the tent and return to Derbyshire, impossible to work in those conditions!
  • Cockpit goes in
  • New floors and engine case
  • Starting to paint the hull inside
  • Calm before the storm
  • Erecting the tent within the tent
  • Preparing for gales in May!

Finishing the caulking and wrapping up for another winter

DSC04722July 7, 2014 finds Steve and Simon in Suffolk, preparing Cachalot for caulking. Before he leaves for Berlin, Simon makes a perfect job of putting more coats of primer on the hull, and we engage Paul to start work on 22 July while we go to Berlin to visit Julia and Simon.

At the end of July, determined to join in with the Dutch OGA Cross Country Tour, Bev took her bike to the Netherlands on the ferry, joining the fleet in Haarlem to ride and sail with them to Den Helder, returning mid-August after helping Claudia to move Else. But that’s all another story . . .

DSC04746Paul and Steve made excellent progress with caulking and starting with the interior and we return to Derbyshire for a couple of weeks at the end of August. After an epic furniture removal trip to help Kate and Simon (Chesterfield – Barnsley – Matlock – Birmingham – Southampton – Chesterfield in 36 hours) we return to Woodbridge as the weather looks set fair until October.

On 26 September another milestone is reached as Paul completes the caulking and ‘paying up’. We spend another week tidying up and preparing the tent for another winter, concerned as to whether it will actually survive. This really must be the last winter Cachalot spends under her tent! We head for home on 4 October.

Restoring and replacing the engine: 2014

Once we could get outside again in March 2011, Steve started to strip the engine down. There were regular consultations with Jim, research on the internet, conversations with Yanmar dealers and French Marine in Ipswich. Work progressed well, with spare parts ordered and arriving promptly, the engine started to look really shiny again.

With the finishing touches to the engine restoration completed in January 2012 . . . it runs like a dream, with thanks to Jim for encouragement and expert advice, as it waits in the workshop for the trip back to Suffolk.

Simon helped with moving the engine back down to the waiting Bongo for the return trip to Woodbridge in July 2014, and we enlisted the help of Tidemill staff and their new JCB, to lift it back into the hull.

This feels like another major turning point in the project!

Planning for caulking and thinking about the cockpit, 2014

DSC03019

It’s April, Easter weekend, and we’re off to Suffolk for the first time this year for the OGA Tollesbury Rally.It’s still too cold to stay long enough to do much on the boat, and we need to get back to Derbyshire anyway where we’ve left Neil and Joe tree-felling in the garden!

2014 looks like it’s going to be another late start for work on ‘Cachalot’, due to the weather, but Steve’s been making good progress in the workshop at home with the component parts for the cockpit all ready to go. Now the hull’s pretty well finished, we’re also thinking about caulking and what to do about the interior, before replacing the deck.

Painting the cockpit

The May Spring Bank Holiday looks set to be fair, so we load the van with the first bulkhead and cockpit sides, made of marine ply, routed to simulate tongue and groove. Carefully put together from patterns, 300 miles away in Derbyshire, Steve starts to fit them all in place. Not only is the hull taking shape, we’re getting started on the ‘fitting out’!

The other major job is to prepare the hull for caulking, filling any minor blemishes before applying more coats of primer. In search of some sunshine and warmth though, we fly off to Italy for a week on the Amalfi Coast at the beginning of June, back in time for Steve to take part in l’Eroica Britannia based at Bakewell Showground.

Sorting out the sheer and painting the hull

DSC01423Paul’s available to do some work during August, and there’s the usual beard-tugging, sucking of teeth and considered conversations as Steve and he discuss what to do about the rudder tube, and queen plank over the counter stern. It’s all agreed and Paul starts work. As we depart for Cowes, and the final OGA Anniversary celebrations, August 2013, Paul continues working on the rudder tube, and we leave the van safely stored on Jo and Paul’s drive. We’re going back to Derbyshire from the Isle of Wight, for a couple of weeks at home.

DSC01396Returning to Woodbridge in September, it looks like the weather’s set fair for us to carry on working for a couple of months. With the tent open on all sides, and the hull pretty well fair, its time to sort out the sheer.

After careful skimming with the plane, Steve and James (who’s popped by to see how we’re doing) keep taking another look, just to be sure, and the starboard side is done. With more good weather forecast into the Autumn, we’re on track to get the hull painted to protect the wood over winter.

While we were in Cowes, Paul finished the rudder tube and now its time to fit the queen plank. There’s lots of discussion about how to ensure the ‘slope’ is right for the deck over the counter to drain properly.

With a final check of the hull, there’s a few more bungs needed to be made, and glued in place. It’s an important job, to get the sheer right, and difficult to judge. So we enlist the help of Trevor and his brother this time, to help get the line just right on the port side.

DSC01665Henry the vacuum cleaner has been a permanent resident in Woodbridge this summer in an attempt to keep on top of all the dust and woodshavings. Once the hull is ready, Beverley helps with cleaning it down, ready for painting with yacht primer.

Take a last look at the lovely wood, before the paint goes on! As the weather becomes more autumnal and the days get shorter, its time to go back to Derbyshire for birthday and anniversary celebrations. It’s been a good year for both sailing and boat building, we did some sailing, joined the OGA50 celebrations and managed to get the hull painted as planned.

DSC01726But there’s some bad news, the tent is beginning to show its age. The battering it’s had over the past six years has worn the fabric in the roof. Now the hull’s got no drainage holes, the last thing we want is for her to fill with rainwater, so its off to buy more tarps for laying up this winter, and we create a ‘tent within the tent’ for ‘Cachalot’.

Ready for fairing, and some summer sailing, 2013

Bungs and glue

Although all the planks and frames are done, there's still lots to do before the hull's finished. Thousands of bungs, carefully made over the winter, have been counted out into coffee tins. These need glueing carefully over the fastenings, with the grain going the right way, of course. Beverley's banned from this task, as she just can’t get the grain going right! There's a bit of repair work here and there, as well as checking over knots and glueing bungs to replace them if necessary. The excess putty needs cleaning from the seams at all the butt blocks. Beverley's role in all of this is to keep everything shipshape, get the provisions in, maintain the archive, keep the business going, do all the cooking and a few of the less skilled work on the boat itself.

Derbyshire, Dublin and back to Woodbridge

With the weather still cold, we stay in Derbyshire, catching up with work in the office. There’s a trip to Dublin in May, to meet the OGA Round Britain fleet on passage, so it’s June before we get back to the boat. Beverley stays in Derbyshire, as her Mum’s in hospital, and Steve makes a good start on fairing the hull. Despite the back-breaking nature of the work, he’s not suffering too many aches and pains either!

After ten days sailing with James on ‘Kestrel’, in the OGA Jubilee Cruise from Ipswich to Brightlingsea, we return to Woodbridge in beautiful sunny weather, at last. As its set fair, we can open up the tent to work in the fresh air and Steve gets into the swing of fairing the starboard side.

Jubilee Cruise: July 2013

Good progress with fairing the hull

After a couple of weeks in the sunshine, with the tent opened up, Steve’s pretty well finished fairing the hull, another important milestone! There’s been more visitors than usual to keep us chatting, locals as well as yachtsmen from further afield. They’re attracted by seeing what’s beginning to look like the hull of a beautiful boat in the furthest corner of the Tidemill. It's known to some as ‘death row’, as we’re very close to the bonfire and the neglected boats ashore gathering rainwater in their cockpits.

Six years on: spring 2013

Bongo has a refit, and we venture down to Suffolk

The entry for 15 April 2007 declares Cachalot a ‘project’. Six years on and we’re still enjoying the challenge. BUT, six years had taken its toll on the Bongo, and she’s overwintered at Full Circle Autocare Ltd. for new wheel arches, door sill and tidying up of dents, bumps and scratches in the paintwork.

Richard and Jim have done a great job, and we’re looking forward to getting back to Woodbridge just as soon as its warm enough!!! When will the winter end??

21 April 2013

Its the start of the OGA 50th anniversary celebrations this weekend, so we're off to Heybridge Basin to say 'farewell' to 'Witch' and 'Bonify', despite the weather, as the first boats leave on their four-month adventure.

Back in Woodbridge, we begin to make plans for this year, after another late start due to the very chilly winter . . . its still bitterly cold at night and we cuddle up in the van with extra blankets, duvets and woolly socks! We aim to get the hull ready for painting this summer, and start by thinking about the deck . . .

What about the deck?

We turn our attention back to the deck . . . after researching the options and having some test pieces of the old teak deck sawn at the woodyard in Tansley, it's decided! The remaining foredeck will have to come off, allowing for a complete new marine ply sub-deck, a layer of glass to ensure we have no leaks, then the sawn teak will be re-laid. The Tansley woodyard has agreed to saw all the stock provided we supply it to them completely clean, with no stray fastenings to wreck their saw. So there's lots of plans and more measurements to be done. Fortunately, the inside of the tent isn’t too cold up on the deck during the day, and with the door closed and several warm layers, the van’s not too bad either.