When you can't fall back on Christmas

Last night I cleared away the Framing Bay and moved the Hornet model into position in preparation for Wednesday's working session. I then layed out the rough shaped spars and spar blanks that have been made so far, and sharpened my planes, drawknifes and spokeshaves. I'm working on a better way to cut the four-sided blanks down to eight sides and realizing that I need better tools. I mean don't get me wrong, our tiny little band saw is great and all, but I need something with a bit more heft to it. Likewise the table saw - that thing makes me nervous sometimes. Christmas is a long way off, so going on a buying spree just isn't going to happen, especially with the caliber I need.

In times like this I go to my couch, pull off all the cushions, and gather all the spare change I can find. If it shakes out to be $1.50 or better (more than likely), it means I can go to the Navy Woodshop at Naval Station Norfolk! For 150 cents of your lost pocket change, they'll let you use all the great tools that I'll bet came off an old tender somewhere - they're just too massive and nice, in a 1950s sort of way. They run like champs, cut like butta and have all the bells, whistles and jigs you could hope for. Plus, the helpful staff there knows so much more about woodworking than I do - even if they don't have a clue what we're making!

So, anticipate a few trips there to knock out the spars and associated gear: masts, caps, tops, crosstrees, yards, poles, gaffs and booms (its not as bad as it sounds - famous last words) for the model. We'll also get a jump on blocks and deadeyes while we're there... and if you thought spars were fun, wait for the sober tedium of making these bad boys! Should be fun... maybe.

BT

Working sessions are Wednesday and Friday nights at 7 PM - come on out and lend a hand on the model as well as our real boats. Monomoy No. 1 is undergoing a routine cleaning, scraping and painting and installation of a new leeboard in preparation for Conquer the Chesapeake 2011.

NNNN

Something's lurking... don't think I don't see what you're up to

There have been many things rumbling around the dockyard lately, and I do mean rumbling.

For starters, the new ordnance carts we purchased to move the new 3-pdr gun and all its equipment have been shuffling in, out and about. I've noticed one of them is a little - um - bent up (?) and we don't even have the gun barrel in yet. Reports said the carpenters were moving trees? Riiiiight. Well at least we can look forward to getting that gun barrel in today (yes, it is arriving today, truck freight) so maybe that will keep those damned rolly rolly wagons out of my way.

Another rumbling around is the sound of the truck we use to haul the Monomoy trailer. The high pitched wisp wisp wisp is probably a clutch needing to be replaced. Where is our motor mechanized division when we need them? Maybe we need to start looking hard into something beefier.

And the last rumbling - that everyone thinks I know nothing about - I hear talk of a "secret weapon". In and amongst the conversation I hear the word "womper". Don't think I haven't seen that movie and don't know what you're talking about. Anyone who is planning on stuffing more canvas onto a boat needs to have it properly approved first. Don't waste your time trying to produce something that will only get shot down in the end. Enough said.

Now, on the same note, if you want to produce another, larger sail, you can start doing some math. Prove to me your concept could work and we'll talk about getting it made. I rather like the idea of an alternative "fair weather" rig for the Monomoy... just don't pretend that you're going to hoist anything up that mast so much as a napkin without my approval.

-Will

NNNN

There's no stopping this tough boat - or her crew!

Yesterday was our last training session for Conquer the Chesapeake 2010 - an event happening later this month where we will attempt to row and sail across Chesapeake Bay from Cape Henry to Cape Charles. The training sessions are meant to introduce new crew members to the boat, and exercise our skills, both in seamanship and teamwork. Yesterday was certainly the best training session we've had yet, providing both a great time and a fair share of challenges for the crew.

Getting underway from the MWR Marina at Naval Station Norfolk around 1000, we stood Northwest for Strawberry Banks in Hampton. Sailing well, we made about 6 knots as we entered Hampton Roads. However, it was there that we met our first challenge, when the yard sprung at the halyard tye. After unbending the sail from the yard, we bent it onto one of our oars, and hoisted that instead. The oar served well as a yard for the remainder of the trip, despite the unsightly oar blade protruding forward of the sail.

Our next challenge was on landing at Strawberry Banks, where our tandem anchor rig fouled and caused some confusion. Designed to moor our chase boat offshore, the messenger line became twisted at the buoy block. The monomoy crew re-embarked, got underweigh and fished the anchor and re-rig the messenger line, maneuvering without the aid of the steering oar with great success. Rack up one more victory for teamwork and good oarsmanship.

Getting underway from Strawberry Banks, we rowed Southwest into Hampton Roads and anchored for lunch. The transfer of stores from the chase boat to the Monomoy went much more smoothly than last weekend, the packages being securely sealed and tossed from boat to boat as the chase boat made a quick pass.

On the way back to Norfolk, we made good time until swept by the ebb tide over the Hampton Roads Bridge Tunnel, where we stepped our mast and rowed back into Willoughby Bay under the East bridge. Again, some teamwork and a hard pull at the oars managed to get us the half-mile into the bay directly into the wind and a three knot current.

Hard rowing, great sailing, repairs on the fly - a great session.

So to all who came out, thanks for another great day on the water!

BT

A new yard for the Monomoy (a solid piece this time) is being measured and trimmed from one of our spar blanks later today. The shop will be open from 3-7 pm, so come on out and lend a hand.

BT

All Monomoy crew for Conquer the Chesapeake have been notified. Due to privacy concerns, we are not posting the names online. Stand by for more information about event preparation later this week.

That's all for now!

Will

NNNN

What AM I angrily shaking my fist at?

One of my navy mentors once remarked something to the effect of "young people should be tired." Work hard, play hard sort of thing. Well, even after sleeping for 9 hours last night I am still tired from the weekend, and moving around like I've got some sort of spinal/muscular disease. Need to shake out that reef - I'd go for a run but it's pouring rain now. And I don't think I'd make it. But I digest.

This weekend we had a mass convergence on the Dockyard, with the goal of stripping and refinishing the Monomoy's oars, thwarts, platforms, stretchers and bilge boards. Those of you who've been out to working weekends know that as the weekend progresses, and various complications arise and are overcome, I get more and more crotchety. This seems to coordinate with teams near completion of their projects and start goofing around a bit, their mood lightening - which means that the more I growl and shake my fists at people, the more apt they are to laugh it off. Looking back on it, it's always kind of funny.

Saturday was the largest showing, with members from as far north as Washington DC and west as Danville VA came out to help. In and amongst the important statistics I should report - the Dockyard crew polished off 14 pots of coffee and 16 two-liter bottles of Coca Cola. Definately worth reporting. Maybe we should get some sort of hook-up from Coke or Juan Valdez, hmm.

Anyway, back on topic. I'm tired and only on my fourth cup of coffee. Focus.

BT

One thing about yesterday that was interesting was the oar refinishing. I got a last minute tip from John Collamore of the Colonial Seaport Foundation to coat the oars in epoxy before varnishing. We had some extra West System goo that the Spar Team didn't need, so that's what we did. Turned out great, so thanks for the tip, John. But I have to say that having people walking back and forth across the yard from the back forty where they were stripped to the framing bay where they were expoxied, then on to the lofting bay where they were set up for varnishing was like watching an accident waiting to happen - I kept waiting for someone to come running around a corner and get clotheslined by an oar. Fighting the constant battle of where to sand and where to varnish (leeward and windward respectively) was my biggest challenge.

But it was good to see so much activity. And thanks to all those who came out to support operations. Sorry, no photos yet, but we had to rush and cover everything at the last minute due to the onset of darkness and rain yesterday. End result, the woodwork is varnished, oars are just about ready for leathering, and we actually hoisted sail for the first time on Saturday. We just have rigging and the racing stripe left - then we get to see our work pay off a bit - or at least put it to the ultimate test... sea trials.

Two weeks until the 'gruelling test sail'. I need to think of something else to shake fists about, 'cause I'm pretty damned satisfied with the work done so far. Thanks, everyone!

Will

NNNN

One milestone met, three to go.

Yesterday the product of the great mast-a-thon successfully passed testing - with flying colors - and was stepped in the Monomoy. The step needed a little shimming - it was 3/32" too far aft - but that was easily remedied. A busy but productive week is over, and a critical milestone met. Congratulations to the spar team - you guys rocked out this week and you've already seen some of the fruits of that labor.

But don't rest now, folks, we still have three more to go. A summary of the work, and the schedule to do it on, is as follows:

Power cleaning of the non-skid deck (in prep for painting) is scheduled for March 20.

MILESTONE #2: Re-finishing. All 11 oars (including the steering oar) and the thwarts need to be totally stripped, varnished, the oars re-leathered and the woodwork and hull attachments caulked. The bulk of this work will occur weekday evenings at the dockyard and next weekend. Completion date March 26.

MILESTONE #3: Interior Painting. The entire interior of the Monomoy needs to be prepped and painted spar and blue-gray. This work will occur the weekend of March 27-28. Completion date (allowing for touch-ups) March 31.

First launch of the season, April 2. Sailing rig not required. April 3, at Nauticus for the conclusion of the Real Pirates exhibit. SIDE NOTE: I realize this is Easter weekend - actually we just realized that this past weekend. Consequently, we will wrap up operations on Saturday no later than 1600.

MILESTONE #4: Rigging. Cutting, set up and fine-tuning of the Monomoy rigging, including all redundant equipment (mast fish and wouldings, emergency rigging, etc).

Painting of the "racing stripes" (navy blue and yellow-gold gunwale stripes) will take place on April 10.

Shakedown sail and training for crossing the Chesapeake will take place on April 24.

Busy times ahead - keep the noses to the grindstone and before you know it, we'll be on the beach in Kiptopeke.

Will

Respite, at long last.

After our recent trials and hair on fire emergencies, we have a few things to be excited about.

Last night I received a phone call from our friendly neighborhood MSC representative. The Military Sealift Command actually owns the 26-foot Monomoy Pulling Boat, and we have to screen all of our programming through them for approval. Their rep was very happy to report that our Chesapeake Bay crossing, known as "Conquer the Chesapeake 2010" has been formally approved. Because of the hazards involved, this particular event required higher level authorization. After all, the prospect is pretty daunting. So approval was the last major hurdle to get over before going, and we are now there. Thanks, MSC! We won't let you down.

The last lamination of the replacement mast was completed last night - tonight we start shaping, one full day ahead of schedule. Impressive, really, to think that on such a short timeline and budget we're still able to pull ahead. By Sunday we should see the mast stepped for the first time, and begin our afloat stability tests.

This weekend I expect a full round of visits as we work the remaining issues to conclusion. Reps from MSC and the Navy will be stopping by to see what we've done so far. Remember, first launching is April 2 at Harbor Park, and our first full scale event is April 3-4 at Nauticus as part of the conclusion of the Real Pirates exhibit.

Will

Numbers are your friends.

Everyone around the dockyard knows that I am a huge fan of proving the various merits of things mathematically, also known as running the numbers before starting a project. For instance, if you're going to build a boat, you want to have your sail plan and stability tables and everything else worked out before you start cutting up lumber, right? Right. With the rapid production of the new mast for the Monomoy to meet our deadline this Sunday - also known as the 'great mast-a-thon' - everyone seems to be in the number crunching vein! It's great!

Side note - those of you with filthy minds need not contemplate alternative meanings of 'mast-a-thon'. Enough said.

Back on topic - it was great last night to recieve sets of calculations from not one but TWO members of the spar team who were working out the strength to weight ratios of the new mast to the old, and comparing them to solid spars. One even went so far as to include a re-evaluation of my calculation of the forces upon the mast step and collar. Well done, gents.

I have to say, though, that I think some may be getting a little carried away here. This morning, I found this picutre pinned to my cork board. Ahh, children. I think I'll keep it there a while...

MAST making! its about MAST making! Christ people get your minds out of the gutter!

Will

You can't spell SLAUGHTER without LAUGHTER

Yesterday, day 1 of 6 in the incredible mast-a-thon, we managed to settle on a design and purchase new material. Picking through two huge stacks of 2x4s we were able to locate the requisite four clear, straight grained ones and strap them haphazzardly to the roof of my x-terra. The drive back to the dockyard at 25 mph was like sifting through the debris of a major natrual disaster that had just happened. Three guys- dirty, tired, sore, one with a huge bruise on the side of his face. Expoxy stained and worn.

Every second of free time to that point was spent arguing over how to proceed, what design to use, where to purchase material. All punctuated by someone randomly yelling "there just isn't time!" periodically. This great wailing and gnashing of teeth continued all the way to the store to buy what we needed, and I'm sure Home Depot did NOT appreciate three guys picking half the pile of 2x4x16 stock out and laying it across the floor of the lumber aisle - all to loud shouts and plenty of cursing.

Side note: gents we really need to mind the language around the kiddies. Otherwise, I'll buy you those electronic dog correction collars to wear when we go out in public. Mother F- AAAAAAAHHHHHHHHH damn it!

So when everyone was perfectly quiet on the ride back - waiting for the 16-foot long lumber to break loose and slide off my roof at any moment - cars honking because I was driving so slow - the faint sound of the red warning flag fluttering on the back - it really was like 'the aftermath'. Thankfully we're well set up to crank this thing out by next Sunday.

The schedule is as follows: today, Wednesday, Thursday and Friday laminate one of the four sides each day. Drink heavily while the epoxy sets up. Saturday, shaping, fairing and varnishing. Add hardware and test - moment of truth - Sunday morning.

Looking forward to continuing another exciting week at the dockyard...

Will

If at first you don't succeed, break out the boarding axes

This morning I've been in a zone I've not found myself in for quite some time. After five weeks of steady work to produce the mast for the Monomoy, it failed the stress test - with horrific results. The 16' mast was rigged and sent through its paces - first compression testing proved satisfactory. Then it was rigged for an analysis of bending stress. At just over 200 lbs applied to the center, a sickening crack resounded in the lofting bay. A laminated joint had failed, causing it to separate and the forward three staves to spring. The finished mast needed to withstand 220 lbs of force at the center - not that much strain, considering that it equates to me sitting on the center of the mast supported at each end. Thirty seconds after the failure, boarding axes were swinging and the test rig had been cut away. The spar team then forged ahead with full axes, reducing the abominable failure to splinters in about three minutes flat. Axes stowed, and one or two beers later, the spar team was brainstorming ways to produce a new mast - that will pass structural testing - in less than a week.

I am officially joining the spar team for the remainder of the week to get this thing knocked out. We have one fifth the time to accomplish this task, and less than half the budget. We may admit defeat, but we must never give up. After all, we can lose the battle, but still win the war.

Will

Masts - the most popular spars in the Dockyard

Since the spar team has set out to laminate a lightweight mast for the Monomoy, we've had a lot of activity and discussion regarding these most essential of spars. And hey, what's not to love about masts? They are the basic facilitators of the back, arm and upper body fatigue preventing devices known as "sailing rigs" - something all oarsmen should be grateful for. From the technologically evolved to the most simplistic, there are a myriad variety with different uses, applications and methods of construction.

The most basic mast in the inventory is a "stand by" mast for the Monomoy which is made from a solid piece of Northern White Cedar. 15' 6" long and weighing in at 69 lbs, it is a force to be reckoned with. Honestly, I hope it becomes something else because the behemoth seems way too massive. But the numbers check out, so for now it is in reserve. Production was exceedingly simple - the spar crew went out behind the lofting bay, into the woods, selected the live tree of the correct size, then proceeded to chop it down. Still green, the tree was then stripped of branches and bark, and otherwise cleaned up. And while there hasn't been much in the way of shaping done, I'd wager it wouldn't take long to fit to the step.

The most advanced mast in the inventory is the primary mast for the same boat. Also 15' 6" long, it weighs in at just 22 lbs. The number crunching reveals only a negligible decrease in strength over a solid spar. Of course, between procuring choice lumber - all select pine - cutting, milling and planing the staves, scarphing, and laminating the mast, there are probably more than 50 man hours invested so far. So not as quick, but worth it if you have the time.

On a side note, the mast for the 24-foot Launch will be much larger and stouter than the Monomoy's - so that's something to look forward to (yikes!).

Of interest to the carpenter's crew - the fitting of the halyard sheave in the top of the mast is coming along - expect that to start soon. Parts are already spinning and chopping in the back - yes I can hear you back there and I know what you're up to. That's what I do.

BT

Side note - whoever is leaving coffee cups on my bench should know that I keep spilling boat soup in them. So no, that's not the coffee made badly, that's pine tar. Just sayin.

Will

Takin' care of business

This weekend was highly productive - the spar team managed to get the mast for the Monomoy laminated and turn all those toothpicks in the shop into a sloppy mess of epoxy and clamps. That'll be fun to see when it emerges after shaping. One thing is certain, that the clamped up spar weighs far less than the standby solid mast of the same size.

The carpenter's crew also managed to get the mast step and collar largely complete, solving a few major structural issues we had in getting the new mast into the boat. The step and collar were omitted in the 1988 rebuild of the boat, and improvements made during that time removed a few key components in the original construction that supported those elements. The replacements take into account the original design but also some design changes to adapt to the rebuilt structure.

The sail is nearly ready for roping and grommets, and is now about 75% complete. It should be ready for hoisting about the same time that the mast, yard and rigging are complete in the middle of March.

Future opportunities at the Dockyard:

Complete interior refinishing is scheduled for March 20-21.
Exterior painting, including the addition of a new blue and gold "racing stripe" is scheduled for April 10-11.

BT

A new plan of attack has been formulated for our CONQUER THE CHESAPEAKE event in May. Due to the high level of interest, we will be assembling two crews - one to take the boat on each leg of the round trip. The BLUE crew will take the boat North, from Cape Henry to Kiptopeke, while the GOLD crew will return from Kiptopeke to Cape Henry. The crew that is not in the boat will be present at departure and arrival, and handle logistics in between. Both crews are invited to take part in the overnight camp at Kiptopeke.

Training sessions have also been moved. We will now have two separate dates, that can each accommodate 10 prospective crew members. All prospective crew members must attend one of the training events, and the final crew rosters will be published soon after.

Training dates are as follows:
24 April 2010 - 0600-1500, Naval Station Norfolk, Norfolk VA
1 May 2010 - 0600-1500, Harbor Park, Norfolk VA

More information will be put out once applicants are registered for training.
So - lots going on. Keep checking in for further updates as we progress - and don't forget to register for CONQUER THE CHESAPEAKE before we fill up!
Will

Cutting edge technology symposium

I know I've already made the obligatory Friday post, including the introduction of FULLBORE FRIDAY, but this was too groundbreaking not to post.

Now that we're taking advantage of the wonders of modern technology such as hollow laminated masts I think its about time we reevaluated the NHS Dockyard Motor Pool. On base today at the NAVFAC Motor Pool I discovered what could become the most useful vehicle in our arsenal. And you would never guess to look at it.

With a 13,000 lb drawbar pull this impressive vehicle is capable of towing both the 26 foot Monomoy and 24 foot Launch simultaneously. Inside there is seating capacity for both crews (20 people), and a well stocked mini-bar for pre-launching liquid refreshment. Even without 4WD capacity, it can scale obstacles as high as 27 inches and wade through water as deep as 5 feet.

As of yet I am still unsure of the price tag for one of these little gems, but I've been told they are completely unobtainable. I think with enough time spent surfing the internet we could easily locate a disused vehicle on eBay Motors somewhere in Ghana or Cameroon. In fact, I'm almost sure I saw the same thing in the latter two years ago.

So members, take a round turn and let's make this the next addition to our glorious Dockyard!

Will

No birds were injured in the making of this mast

IT'S FRIDAY!!! And I'm getting pretty excited for the weekend - lots of work going on. For starters, we have the Monomoy mast being laminated. It's being made in a "bird's mouth" technique that produces a hollow mast weighing a fraction of what a solid spar does with only marginal strength loss. The mast is 16 feet long and is 5" in diameter at its widest point, tapering to 3.5" at the masthead and heel. The pieces are already made, for the most part, and the spar team will be making final touch ups and laminating tomorrow. In the paint shop for some varnish next week and hopefully we will have the finished reproduction mast ready to go.

Also this weekend we have the naval carriage for the 3-pdr being fleshed out a bit more. Depending on shipping and logistics, we may have the gun itself in time for GCH. Sorry, guys, she's not going even if we have her - doesn't fit in with the program.

The foot and leach of the sail are now complete, sans roping and grommets. Corner patches are installed at the tack and clew. Tonight I plan to cut the tabling for the tack and head, and get them started as well. The Manila line that was on the stretch in the rigging cage came out yesterday, and will serve quite nicely to rope the sail's edges. All in all I think a mid-march finish date is more than practicable.

So, in closing, I intend to start a tradition here on the NHS Dockyard Blog - in tribute to one of my favorite Navy bloggers, I'm going to call it FULLBORE FRIDAY - something like Jon Stewart's 'Moment of Zen' but a little faster paced. This week's subject is brought to you by those crazy Aussies at Ocean Thunder pro surf boat racing. Because nothing says cool like rowing through pounding surf and having your boat flipped and oars broken - while wearing speedoes. Rock on, Australia.

Will

By our powers combined...

If you know what that was from, you're probbably in your late 20s suddenly feeling kind of old. At any rate, I'm calling in the big guns on several projects that are clogging up my lofting bay. This Saturday and Sunday we'll have

1. the Mast & Spar Team setting up the lamination for the replacement Monomoy mast. I'm sick of kicking around your toothpicks, go make something large and impossibly lightweight out of them.

2. the Gunner's Mate and his crew finishing the axles for the 3 pdr carriage. Those chunks of oak are about to become keel blocks or heating elements for boat soup. Chop chop, fellas.

3. both teams are to supply at least two bodies each to grunt labor in the Monomoy prepping for new paint.

Lots of work to do before our April 2nd launch date. So come on out this weekend, and let's get 'er done!

Will