These are what we call 'collateral' duties...

Here at the dockyard, we have four or five huge crates filled with seemingly random pots and pans, iron pieces, hooks, chains, whips - no those are on my bench - and assorted other hillbilly cooking apparatus. I've tried to explain to volunteers that those are for field messes - to feed the sailors and marines (who up to this point are largely fictional to most volunteers) at events. At the Dockyard, we are not only responsible for the boats and new construction projects but also tents, cooking gear, and any other equipment that doesnt fall into uniforms or weapons - though we also manage guns (shipboard cannon) as well. So for those of you who've been asking why we have tent stakes, timber axes, grappelling hooks, canteens, haversacks, bolts of "non-sail" canvas and racks of colored tent poles, that's why.

Yesterday I began breaking out stores enough to supply the marines at the Battle of Guilford Courthouse coming up this weekend. And as the crates of mess gear started coming open more than a few people asked "how do you expect those guys to eat out of those things?" Good question.

When the pots, most of which are made of tin, were stored last, their coating of tallow was not sufficiently applied. When properly cleaned, coated and crated, they will last for months without maintenance. However, these had not been coated, and had been badly cleaned. I've never had to scrub scale out of pots - until last night. Be assured I will be checking all returned inventory before it comes in - I'm not doing this again.

This is also most people's first exposure to the field issue system of organizational property management, aka the supply system. Everything that NHS owns is carefully documented and tracked. I am proud to say that we can track any item we own, find out where it is and whose responsibility it is to keep it. If it gets lost, stolen, damaged or destroyed it gets documented. Its a remarkably efficient but time consumingly meticulous system. And now you volunteers know the importance of the Superintendant's Ledger on my bench - where we record what comes and goes from the Dockyard.

Registration for marines is currently closed for the Battle of Guilford Courthouse 2010 - the ranks are full and we have no more gear to issue. Sailors, your time will come - besides, there isn't a boat for miles where we're going. But I encourage as many as want to make the trek to come out and see us. It should be a great time.

And all the while, work goes on in the Dockyard. More on that tommorrow.

Will

Something else to get excited about

I've been quite verbose about our preparations to cross the Chesapeake in the Monomoy Pulling Boat, but I haven't said much about the other projects underway at the dock yard. Soon after the Monomoy is finished and re-launched, our first gun is set to roll out of the shop.

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Our first piece is a 3-pdr Naval Gun, the sort used throughout the 18th century but most notably in the Revolutionary War. It was just about the smallest gun mounted on its own wheeled carriage, but don't let that fool you. The barrel weighs 250 lbs and is capable of lobbing a three pound ball (hence the nomenclature) more than half a mile! It is made of iron cast around a seamless steel tube (for safety) and is manufactured by Lion's Den Arms of Ontario, Canada. Her naval carriage weighs approximately 100 lbs and is being made from white oak. For more information check out the Naval Gunnery Links on the resources for sailors page of the NHS website.

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When completed, the gun can be situated on skids in the bow of a boat, or used ashore for saluting and drills. We plan to make her a regular sight at our live fire events, and when the marines bring out their small arms, the sailors will bring out the gun. I'd be amazed if there was much of the target left when the sailors were done with it. And I'm sure sailors will really enjoy showing off their "big gun" to all the ladies on the waterfront wherever we go.

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In other news, the sail for the Monomoy is wrapping up - grommets and cringles are now being installed, and she should be finished and flying within the next two weeks. There is a rough spar blank in the framing bay that I assume is going to become the yard for her before very long.

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The carpenters are mulling over an assortment of oars recently received, working out a process to standardize them for use in several different boats, as required. They're also stripping down the Monomoy oars in preparation for painting and re-leathering. Note for you guys - the new leather is here, check out the round package on my bench.

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So if you've only been following via blog, you're missing out on lots of other activity at the dockyard. With the constant work progressing on a daily basis (literally!) its difficult to keep track of it all here. So get in touch and come on out - see for yourself the gems our members are working on. And of course keep checking here for the latest and most significant developments as they progress.

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Will

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