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-   -   How to repair a pulled forestay tang on a classic yacht... (http://www.sailnet.com/forums/gear-maintenance/92927-how-repair-pulled-forestay-tang-classic-yacht.html)

CharlieCobra 10-10-2012 12:41 PM

How to repair a pulled forestay tang on a classic yacht...
 
As some of you folks recall, the Lady suffered a forestay tang failure while under sail to windward. Luckily she didn't lose the rig and was able to limp back to us under power for repairs. Here's a look at the damage:


http://i234.photobucket.com/albums/e...0issue/004.jpg


http://i234.photobucket.com/albums/e...0issue/001.jpg


Once we got her hauled and the rig down, the hard part came. How to repair her without ripping the boat apart? Well, we came up with a plan....


I cut the damaged section of the Stem out in order to insert a "Dutchman" if you will, into the existing Stem:


http://i234.photobucket.com/albums/e...ue/Stemcut.jpg


http://i234.photobucket.com/albums/e...e/Stemcut2.jpg


While taking her apart, we found a signature from her construction.


http://i234.photobucket.com/albums/e...ue/stemsig.jpg


Once I had her cleaned up, including cutting out a section of the foredeck and the forepeak cap: We then made pieces to fit back to where they were, which was not an easy task, starting with the Stem insert:


http://i234.photobucket.com/albums/e...e/SRready2.jpg


http://i234.photobucket.com/albums/e...ue/SRready.jpg


http://i234.photobucket.com/albums/e...ue/SRready.jpg


Then we received the modified tang and discovered a couple of things. First, it was bent during the welding of the additional parts and the design was changed enough that it no longer fit.


http://i234.photobucket.com/albums/e...e/Tangfit2.jpg


http://i234.photobucket.com/albums/e...e/Tangfit1.jpg


http://i234.photobucket.com/albums/e...angfitoops.jpg


Ok, now I get to play Blacksmith... I also had to cut in a recess to fit the new tang top, which created another issue. It left 1/2" gaps to each side of the tang because the back was wider than the front and you couldn't set it in vertically this led to making mahogany fillets to fill the gaps.

The deck was a two layer laminate of a 1/2" top layer over a 1/4" base, with the seams staggered four inches and the whole thing laid up in glass and epoxy.


This time she was thru bolted properly:


http://i234.photobucket.com/albums/e...0issue/016.jpg


Anyway, here's the finished product some 50 Hrs. later.


http://i234.photobucket.com/albums/e...ssue/003-1.jpg


http://i234.photobucket.com/albums/e...ssue/002-1.jpg


http://i234.photobucket.com/albums/e...ssue/004-1.jpg


http://i234.photobucket.com/albums/e...0issue/005.jpg


http://i234.photobucket.com/albums/e...0issue/021.jpg


Hopefully, the owners get to sail her a while before bringing her back to us...

smackdaddy 10-10-2012 12:46 PM

Re: How to repair a pulled forestay tang on a classic yacht...
 
Wow. Nice work.

I was wondering how you guys were going to tackle that one.

CharlieCobra 10-10-2012 12:59 PM

Re: How to repair a pulled forestay tang on a classic yacht...
 
It was a challenge but not impossible...

Gene T 10-10-2012 02:06 PM

Re: How to repair a pulled forestay tang on a classic yacht...
 
Nicely done as usual. You continue to impress me.

Gene

casey1999 10-10-2012 10:07 PM

Re: How to repair a pulled forestay tang on a classic yacht...
 
Was original tang bronze and you welded the break?

Nice work....

dacap06 10-10-2012 10:15 PM

Re: How to repair a pulled forestay tang on a classic yacht...
 
Wow, Charlie. I must say that is an awesome job! What craftsmanship!

Tom

CharlieCobra 10-10-2012 10:48 PM

Re: How to repair a pulled forestay tang on a classic yacht...
 
Quote:

Originally Posted by casey1999 (Post 931915)
Was original tang bronze and you welded the break?

Nice work....

The original tang didn't break, it was just too short. The extension and the breastwork sides were welded on and yes, it is silicon bronze. No, we didn't weld it.

arf145 10-11-2012 07:56 PM

Re: How to repair a pulled forestay tang on a classic yacht...
 
Charlie, your work just makes my day! Really!


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