We bring our second part of the story of making a new gaff for ‘Excelsior’ from our ‘sawdust maker’ at the Excelsior Trust.
Initially, when I started working on boats I believed that it would mean I just had to learn which end of the chisel to hold. Reality though is much different. My first wooden boat was an absurd learning curve. To make progress, you need to try most things. Or know someone who can. Thinking like this, well it needs to sit with an understanding of causes of failure, or how to improve something. For any boat, the people who sail them will have insight into what’s needed. It’ll give you more perspective on ways to repair, or even improve gear/components you’re working on.
In Part 1, I’ve outlined the remedial work being undertaken on the main gaff for ‘Excelsior’. The next stage of this is a classic example of having to adapt and learn new skills. Initially though, I spoke with the crew. Knowing the incredible distances the boat covers, they know more than me. A little extra inspection showed that compression had caused some of the damage and some changes were required. Firstly, removing sharp edges! This is dual purpose, it not only improves the aesthetic of something, but also reduces friction of the chances of something ‘grabbing’. With a quick sharpen beforehand, the spokeshaves were brought out. Our first job was to round off some edges, balancing this against strength and anticipating how much the jaws might ‘twist’ in use.
As an aside, most handtools are incredibly tactile and give you lots of signs when they’re unhappy. Now, it’s very niche, but you can hear when they’re sharp. For the sawdust makers amongst the readers, sit back and savour the ‘ssccchooomppfff’ of a clean cut with the blade. Go on. We’ll wait. If you don’t hear that, consider sharpening, adjusting, changing the direction of cut, the ‘lay’ of the grain, or several other things. Just remember the tool will ‘talk’ to you. Visually, the changes to the jaws were immediately apparent, but the hardware also needed thinking about. Again, this is an area I’ve no experience of. However, my good friend Rolls L’plate was on hand to help.
As I say, I’m not an experienced fabricator, so my general principles are/were; it MUST spread the loading across a larger surface area, and personally it also MUST look ‘right’. 6mm steel was then cut, rolled, blued and fitted to the gaff. I was incredibly lucky to be working with some extremely capable volunteers. It’s a pleasure to be able to work like this, especially when cold-rolling 6mm steel (it’s good for them).
Lessons learned: 1. Steel is an odd material (all the blacksmiths can calm down!), I have a tremendous respect for fabricators who make it look easy. Quite quickly we moved onto a different set of rollers, and asked for volunteers! 2. Patterning (as always) saves a lot of time and it doesn’t have to be clever, just know the final ‘shape’ you’re working towards. Knowing my limitations, this was slow progress, but it started to show that we would improve matters, which is always a bonus when you’re wielding tools.
With any job, it can feel like the final stages take the longest. Certainly it does in my head, so loud music and headphones provided a solace while I shaped and tidied up the fitting (note, it’s stopped being just material and is now a ‘thing’). Again, I’d not ever ‘blued’ something before, so setting up a quenching bath and a source of heat, plus handling the red-hot fitting was a new ‘experience’. Still. It’s worth doing as well as I can, especially given that I’ve detracted from the original set up, using my own thoughts (risky…) The generous/skilled volunteers then stepped in for painting and reassembly, with a few other ‘snags’ tackled. It’ll never be as easy to address an issue than when the object in question is in a shed, level and well-lit, etc., etc.
Tightening the clenches was, well it was bloody hard work if I’m honest. Thankfully the boat has an excellent bosun, who resembles some biceps with a sailing knife and deckshoes attached. Giving him a sledgehammer and roving tool was like giving a giant a toothpick if I’m honest! And, as a side-note, he’s 16years younger than me, without tennis elbow. Decision made! Now, the finished article. Doesn’t it look better?
I think I’ve made maybe two metal fittings, ever. Having the opportunity to use the correct tools, understanding the loading involved and having some limited experience to draw from all worked in my favour. Maybe I’ll be there on the throat when the boat goes sailing to see if there’s a difference! Cumulatively, small changes add up. My suggestion would always be to make initial changes that are reversible, except where you are confident. ‘Sailing Trawlers’ and ‘The common sense of yacht design’ were my ‘go to’ throughout. Reference materials, especially with old boats are helpful, but where you can, talk to the people who sail the boat.
As ever, the ‘Excelsior’ operates as a charity, primarily aimed at giving young people a chance to experience adventure, learn skills and gain confidence. I’m delighted to have finished this job, using materials and tools that were available to us, in the shipyard. Made, not bought is usually better and I lost count of the things I had to tackle, all in the name of being a ‘wood butcher’.
If you are interested in sailing on ‘Excelsior’, or wish to support the Trust in other ways, please do get in touch. There are multiple opportunities for everyone at all stages of their sailing. The boat is wooden, gaff rigged and the people you’ll meet are remarkable.
Photos and words contributed by ‘the sawdust maker’
Look out for Part 3, introducing another new skill.
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