Sampson Boat Co · video

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The restoration of the 111-year-old yacht *Tally Ho* requires adding approximately 2.5 tons of lead to the existing ballast keel to lower the vessel's center of gravity and replace weight lost to historical damage.24:39 The project involves melting lead in a custom-fabricated steel pot, nicknamed the "pig," and pouring the molten metal into a timber mold constructed atop the original keel.13:40 To prevent fire and contamination, the team installs fireproof blankets and plywood beneath the keel and wears vapor masks to mitigate lead fume exposure.26:34 During the initial pour, the high-pressure stream of molten lead jets through the existing ballast, creating a leak at the bottom of the mold.32:18 The crew successfully stops the flow using a control valve, and the containment measures prevent fire or environmental damage.32:50 The team plans to clean up the spilled lead and reassess the casting process.34:19 Proper containment and emergency shut-off protocols are essential when pouring large volumes of molten lead near a wooden hull.

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