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The restoration of the wooden sailboat Tally Ho includes the fabrication of a new, hollow, glued-up mast at the Port Townsend Maritime Centre.0:24 The team, led by Robert Darcy, utilizes a barrel-stave construction method, which involves joining eight tapered staves to form an octagon before shaping the spar into a round profile.1:03 This approach allows for optimal grain orientation and weight reduction compared to a solid, grown mast.8:43 The staves are joined using long, staggered scarf joints and bonded with West Systems epoxy.14:34 Internal features include solid blocking at the deck and gooseneck areas for compression strength, conduit for electrical wiring, and a radar reflector mounted near the top.21:28 Separately, the boat’s domestic water system is installed using two Marco pumps in parallel to provide redundancy and flow control.15:35 The project team plans to construct the boom and gaff next to allow sailmakers to assess spar flexibility before finalizing sail designs.24:32

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