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Old 10-10-2012
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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:








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:








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





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:











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.











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:





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

















Hopefully, the owners get to sail her a while before bringing her back to us...
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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.
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Re: How to repair a pulled forestay tang on a classic yacht...

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

Nicely done as usual. You continue to impress me.

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

Was original tang bronze and you welded the break?

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

Quote:
Originally Posted by casey1999 View Post
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.
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Re: How to repair a pulled forestay tang on a classic yacht...

Charlie, your work just makes my day! Really!
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