Sampson Boat Co · video

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The restoration of the 110-year-old yacht Tally Ho involves casting bronze floors and fabricating patterns for hanging and lodging knees.0:17 The hull construction utilizes a backbone consisting of a stem, cutwater, forefoot, keel timber, and stern post, with deadwoods providing structural reinforcement.3:15 Frames support the hull planking, which notches into the backbone via a rabbit.4:43 Hanging knees provide athwartships stiffness by connecting deck beams to frames, while lodging knees provide fore-and-aft stiffness by connecting beams to the beam shelf.6:36 To reproduce the tapered arms of the original wrought-iron knees in bronze, a custom sled jig allows for consistent shaping through a planer.14:40 After casting, the bronze floors are fitted flush against the keel and frames using a feeler gauge and grinder to remove high spots.19:29 Additionally, the hull frames are being faired using a batten to ensure a smooth, continuous curve for the future installation of hull planks.23:53

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