Sampson Boat Co · video

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Leo Goolden fabricates and fits solid teak cap-rails for a wooden sailing yacht restoration. The process begins by creating plywood templates that match the bulwark profile and account for the tenons atop the stanchions.0:46 After transferring these patterns to teak planks, Goolden cuts mortises into the underside of the rails to lock them over the stanchions.4:03 He selects teak stock based on grain quality and natural curvature to match the boat's sheer.8:46 Before final installation, the crew fairs the bulwark planks using planes and long sanding boards to ensure a smooth, continuous surface for paint.10:07 The project also involves finishing the deck caulking with cotton and TDS sealant.13:28 The work requires precise scarf joints, which are shaped with a router and cleaned with a chisel to ensure square corners.12:11 Fitting the cap-rails requires careful alignment of mortises to ensure the rails sit flush against the bulwarks and stanchions.

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