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Restoration of the 111-year-old yacht Tally Ho requires installing 106 individual hull planks, a process currently one-third complete.1:03 To ensure structural integrity, copper rivets fastening the floors to the frames undergo shear and tension testing at a local facility, OSP slings.7:46 Results confirm the rivets withstand loads exceeding 2,500 pounds, significantly higher than the requirements for supporting the ballast keel.8:14 The build team utilizes a custom router jig to cut caulking bevels into the planks, creating a wedge-shaped gap that is tight inboard and open outboard to accommodate cotton and oakum packing.21:36 This traditional Carvel planking method, which involves hollowing the back of each plank to fit the frames, provides greater hull stability and manages timber expansion better than using wider planks.12:40 The crew also performs fine-tuning fairing on the frames to ensure a tight fit for each plank, some of which exceed 35 feet in length.11:53

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