Sampson Boat Co · video

What this video covers

Fabricating the standing and running rigging for the 1910 gaff cutter Tally Ho requires a detailed load study to determine shroud dimensions based on creep rather than traditional strength-based calculations.4:01 By using synthetic Dyneema line instead of galvanized iron, the project achieves a 75% weight reduction aloft while maintaining structural integrity.5:12 Riggers at Brian Toss Rigging perform a Mobius Brummel splice on the Dyneema, followed by a strategic taper of the tail to prevent stress risers.14:49 Each shroud is then tensioned on a 48-foot hydraulic stretching bench to set the splice and measure elongation.18:46 To protect the synthetic material and provide a traditional aesthetic, the crew applies a serving of marlin using a serving mallet, which is then coated with a pine tar and varnish mixture.5:48 This serving method allows for easier inspection and repair compared to chafe sleeves.9:14 The process concludes with leathering gaff span eyes using a baseball stitch with blunted needles.1:24

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