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We numbered up all the deck beams before removing them. Most of them are shot and need replacing but we will use them as patterns for the new ones.
All the old paintwork and anti-fouling has to be removed, inside and outside the hull. A hot-air gun and a scraper is an effective, if time-consuming method. We have found that the tent gets very warm when there is any sun about. Consequently, operating the hot-air gun soon creates sauna-like conditions to work under!
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CODBLOG8 - GWALCH : Let Ribbing Commence
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COD ribs are made from North American Rock Elm. Your common or garden European Rock Elm wont do -- its not flexible enough. It is also resistant to water and besides marine use its apparently used in the funereal business, strangely enough.
Very few of the existing ribs were considered serviceable so we decided to do them all. We wanted 9ft. lengths for most of the ribs. Some of the ribs are shorter but as there are 39 ribs in all our requirement was quite substantial. Once again Rod Yates procured the timber and with his workmate, Bill Macready cut it and planed it all to size and delivered it to our door.
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The original "Knee", the L-shaped piece that supports the bottom of the transom to the keel was found to be useable after a little TLC and this was bolted temporarily to position. It will be secured with silicon-bronze coach-bolts eventually but for now we are using bog standard steel ones to hold it in position so we can mount the transom.
Eventually, after a few dry runs we fitted the transom using Sikaflex sealant on the joint and clamped it in position. We then secured the planks to it using copper nails. A little bit of sanding and the job's done. Result!
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Arthur had been whittling away at the big banana-shaped piece of oak and this week arrived at the boat with the new stem ready for its first fitting. This was the first of several fittings and after each time the stem was "fettled" to get a better fit.
The bottom of the stem is secured to the keel with two large coach bolts and for the final fitting the interface was given a large dollup of Sikaflex sealant.
Martin Williams, who used to work at his father's boat yard, Williams & Nixon on Deganwy Dock, came round this week to see how we were getting on and offered the use of some large clamps that had come from the old boatyard. These came in very handy when fitting the stem. They obviously hadn't been used for many years and we couldn't help wondering about which old boat they were last used on!
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Gwalch has no deck on, so, as you squeeze the sides together the bow pushes forward. Hence the requirement for the clamps -- as we wound them in amidships the bow planks lined up with the new stem.
The end of the planks have been renovated using fibreglass. These were then drilled and nailed to the new stem. The final finishing of the stem can now be done in situ.
After so long with a gaping hole at the front, Gwalch is now looking like a boat again!
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We've finished the ribs -- that is we've replaced all that we think is necessary. There is one original one left which looks OK so it will stay. Hope we don't regret that later but meanwhile it will give us a useful reference point for the next stage.
The Rudder Support Block has been renewed. This was hand-crafted by Jeremy Byrom out a mahogany gatepost provided by Rod Yates.
The Keelsom, which is the big plank inside the boat, sitting on top of the keel has been replaced using a very big chunk of oak which we planed ourselves. Its held in by the keelbolt securing nuts. Its got a curve to it so bending this thick plank was a gradual process tightening the nuts down, putting a turn on them each day until the thing was in position.
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Last year, when this Centenary Project got started and we were arranging to move Kandahar from Gallows Point, Beaumaris to the workshop "tent" I received a letter from a Mrs Rosemary Asher who lives in the Isle of Wight. Mrs Asher's grandson had uncovered some old trophies in her attic and she rembered that her father "had won them at Conwy sailing his One-design boat called Kandahar".
What a coincidence!
I checked our records and, sure enough, her father Clive Preston and his friend Ralph Morgan had been the first owners of Kandahar back in 1930 and their names are on our trophy boards in the Club.
I wrote back to Mrs Asher and told her what we were doing and enclosed a recent photo of Kandahar. I could just imagine her surprise at finding out that the boat had actually survived all these years, let alone was the focus of a restoration project!
I naturally invited her up to see the project and her father's old boat. Last month she and her husband, Andrew, revisited North Wales and joined us at the Club for the "Last Night of the Proms" evening. On the following Monday they visited the Workshop. It felt a bit like having a Royal Visit! Thankfully, they were impressed with the progress (on Gwalch not Kandahar yet) and we look forward to repeat visits and, with a little luck seeing Kandahar back on the water.
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It was time to fit the Rubbing Strips and Top Planks that we had prepared earlier. Handling was the dangerous bit. Having had one disaster through trying to bend one plank too far, Keith and I were now far more careful handling these 21ft planks!
The Rubbing Strips were fairly easy as they were thinner and formed to the shape of the hull as they were offered up. They are then nailed to the plank below along the whole length.
The Top Planks were a different matter. These are tapered at each end. The old planks had been used as patterns and the finished shape is something like a strip of a banana skin, 21 ft long. Fitting them entailed bending the plank around the horizontal curvature of the boat and also pulling it down at the ends to fit flush with the rubbing strip.
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All the old deck beams, bar one, needed renewing. A visit to our friendly woodyard in Trefnant had procured the necessary timber for them. Going round the yard pulling random pieces of timber worked out cheaper because some were a bit bent but still suitable for our purpose. Class rules dictate that the 3 most important beams (at the mast, the tiller and the mooring post) should be oak but the rest can be made out of lighter wood. As we had oak available we went for that.
These planks were planed back at our "workshop" and marked out for cutting using the old beams as patterns. A day trip to Yates & Co. at Stockport was arranged and the whole lot was loaded onto Ron Cheetham’s Toyota and off we went. Rod has obviously been practicing on the bandsaw because we made short work of the job and by the end of the day we had a complete set of deck beams to go home with.
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Fortunately, the gales were not accompanied by too much rain so we we managed to cover all our work-in-progress with borrowed tarpaulins which has given us some time to carry out remedial work.
We had a bit of brainstorming on the repair work and a new roof panel has been ordered. We decided to put extra bracing onto the frame and Keith scrounged some suitable pipework which we've now bolted up. When the new roof is ready we'll get a team together to put it on and hopefully we'll be back in business!
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Work had stopped on the boat because the roof of the tent had blown off with the gales at New Year. Everything was covered with tarpaulins so it was a matter of waiting for the new roof panel to be made.
We had ordered the new roof from Brooke's Tarpaulins in Penmaenmawr and they were really helpful. When they had finished making it we fitted it with a little help from our friends and it fitted really well.
Keith and I repaired the tears in the sides of the tent and made sure everything was well lashed down. Everthing now appears to be weatherproof. Once we had sorted the mess inside, caused by our hurried covering of everything following the storm, we are more or less back in business.
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The next item tackled, also a highly visible one, were the cockpit surrounds, or Combings. The original ones we had taken off were past repair so new teak planks were sourced from the woodyard and cut to the pattern of the originals. We have bolted the combings to the carlins and deckbeams so that (in theory) they could be removed at some time in the future if required. As the four pieces are securely glued and screwed together the whole assembly should come out as one. The front panel in particular was a tricky little number to fit as it was all different angles. We had two goes at it before we got it right.
For those who sail COD's the Combing is a most uncomfortable feature of the boat in that as you sit on the side-deck you have to sit over this 5/8inch plank. The good doctors who had Musetta restored were considerate enough to have a moulding added to the top edge to make it more crew-friendly. All COD sailors look at this with envy so we had to put one on Gwalch! Again, these were hand-made using off-cuts from the same wood as the combings. We stuck the mouldings to the combing using West epoxy adhesive and a multitude of clamps. Next day, clamps removed, we were able to plane and sand and the result is very pleasing.
I just hope that those crewing Gwalch in the future will appreciate what efforts have been made to avoid bruises on their bottoms!
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CODBLOG23: The Paintjob
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We had many discussions, mostly around the bar, about the final colour of the hull. Dark colours are not so good with sunlight (if we ever get any) and we wanted to be different from the many white-hulled COD's. Reds and blues are also well represented so we opted for Cream from the International range.
We had put grey Primocon on the surfaces that would be underwater and Yacht Primer, also grey on the topsides. The break-line between these two, in theory, was the waterline.
Establishing the waterline is a tricky business. Perhaps some sort of laser marker might work if you could make sure it was level AND that the boat was level. Surprisingly, the answer turned out to be on the other boat we had in the tent, ie Kandahar. This has the waterline scored into the hull planks, presumably when it was being built. How this was done originally is still a mystery that we might solve one day! Anyway, we took measurements down the hull at regular intervals from the gunwhale to the waterline and transposed them onto Gwalch. Then it was "Join-the-dots" time using a long piece of flexible plastic as a rule. This turned out to be a 3-man job with two holding the rule and the third marking the hull with a pencil. This performance was repeated several times as we had opted for a white "Boot-topping", a stripe of white Antifouling between the cream topsides and the black antifouling below.
Our paint specialist, Gig Jackson, had set out to achieve a "piano-top" finish to the hull. Unfortunately, we knew that this would be spoilt when the hull took on water after being dry for so long. The planks would then squeeze out the sealer from in-between and create a "railway track" effect. What we didn't realise was that this effect would start even with the paint going on. As the Yacht Primer, the Undercoat and then the Topcoats were applied, the dry timbers sucked in the paint and the sealer squeezed out at the joints. Perhaps next year for the "piano-top finish"!
All the woodwork has been treated with Danish Oil and it really looks good. The Marine-ply deck, having been primed with Primacon was finished with a couple of coats of Interdeck anti-slip deck paint. Gig Jackson and Peter White have put a lot of time in on the painting and the boat is really looking good.
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CODBLOG24: Fitting Out
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It would have been nice to refit Gwalch with all new fittings. Our budget, however, doesn't run to new Harken blocks etc. so we are largely making do with what we've got.
Keith and I did a fair bit of scouting around the other boats in the fleet to try to ensure we fitted the bits in the right place. This is when you find that every boat is different. ONE Design.........HAH!
COD's aren't too complicated. There are also many sailors of COD's, currently or in previous years, who will give you their views on what works and what doesn't. Unfortunately, they are all different and often contradictory!
Naturally, basing it on the "KISS" principle (Keep it simple,Stupid) we put it together as best we could. Time was now running very fast. We had important deadlines to meet. My objective was to get Gwalch to our Regatta in the Menai Strats and time was really tight. Also, we were on notice at our premises. Alun Simpson's nephew, who has inherited the property wanted us off the site by end of August so Gwalch had to be finished pronto.
The outstanding items turned out to be the Bow Roller and Forestay fitting. The latter was purchased from Davey's, a chandler specialising in Classic boat stuff and the Bow Roller was fabricated from stainless steel by David Williams in Builder Street.
The other items that caused concern were the Back-Stay Runners. The original COD Specification calls for 2 Runner Plates for the Back Stays so presumably the various tracks that most boats have got are a more recent addition. The problem is that the leeward backstay has to be let off when sailing downwind to allow the boom to go forward. All COD's have got some device to make this job easier. Most common are runners on the deck with the backstays attached to travellers held in them. There are other variations including one that has levers that look like they come from Deganwy signal box!
It was time to get the mast up. Firstly, to check that the mast step and the mast chock were correct and the mast would fit in and secondly so that we could finalise the positions of deck fittings such as the jib fairleads.
In theory it should have been easy using our lifting gear to get Gwalch back on the trailer. However, this was the first time we had lifted a newly painted boat and we were being very careful not to damage the paintwork. The boat was eventually loaded (we had borrowed Minnie’s trailer) and we pulled it into the open air for the first time in two years.
Minnie’s trailer is a little higher than our own and negotiating the sheds was a bit tricky. We were so intent on avoiding contact with the sides that we didn’t notice that we had hooked a rope from the tent around the tiller. Incredibly, it was not noticed until the next day that the tiller had been forced back so hard that it split.
The tiller was a brand new one formed from an off-cut of one of the oak deck beams which had taken hours to make and lovingly treated with coats of varnish. It was a little heart-breaking to say the least. Fortunately, it was repairable with our old friend, West Epoxy adhesive.
We stepped the mast without too much drama and noted that the shrouds we had would need shortening. This we would do after the boat was on the water so that the mast-rake could be set correctly.
The Backstays proved more difficult. The sliders aren’t sliding and we’re not happy that the tracks are secure enough. A lot of time has been spent on these and we are still not happy. With the clock running it looks like we’ll have to rig a temporary arrangement in order to get it away.
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