Sampson Boat Co · video

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The restoration of the 110-year-old yacht *Tally Ho* requires casting custom bronze floors and knees to reinforce the vessel's structural integrity.0:18 Because the original flask size proved insufficient for the larger floor patterns, the team fabricated a custom, welded-frame flask to accommodate the increased volume.0:50 The casting process utilizes a three-piece mold—cope, drag, and a central core—to ensure proper packing and structural detail.1:05 After initial failures where sand collapsed during lifting, the team refined the packing technique to successfully cast the larger components.4:39 Once cast, these bronze floors are sandblasted, ground, and polished at the Port Townsend Foundry before being installed and bolted through the keel and centerline.10:28 The project also involves fabricating patterns for breast hooks to tie the forward stringers and beam shelves to the stem.18:10 The final structural centerline bolt is driven through the stern assembly following the recent cutting of the propeller aperture.24:06

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