24' exploration gaff-rigged ketch by vaddoc - FINISHED -Scale 1:12, a Tad Roberts design

[Omega1234]

Hi Vaddoc

 

The Butterfly Explorer now has wings!!! Nice job. I especially like the jig you made-necessity is the mother of invention.

 

Cheers

 

Patrick

[vaddoc]

After a long break due to summer vacations I started again work on the boat.

 

I finished and glued the mizzen mast step and the center board case cap that supports the middle thwart and also acts as mast partner. I also made and glued the two small boards to complete the floor.

 

 

 

Next the thwarts were installed, I copied exactly the way the american team used cross beams secured to the frames and the side benches although later on I realised that I positioned the thwart aft of frame 6 instead of forward but no harm done.

 

 

 

 

 

 

I must say I quite like the result!

 

 

 

Next it was time to install the main mast and most importantly the small deck which I think will add a lot to the boat. This proved challenging mainly due to the cant frames which increased a lot the complexity of the built.

 

 

 

 

 

 

 

 

Still a lot left to be done but I am looking forward to see the deck completed.

[Omega1234]

Hi Vaddoc

 

Really, really nice!

 

Good to see you back, again, too, by the way, because I've been wondering how your ship was going.

 

Cheers

 

Patrick

[Jim Lad]

She's really looking first class, mate!

 

John

[captainbob]

What a fine job you're doing.

 

Bob

[vaddoc]

Dear Patrick, John and Bob and to all who hit the like button thank you, your support is much appreciated.

 

I finished the last few components of the foredeck support and epoxied everything in place. I am very happy with the result, it is very solid and completely flat and certainly would work in the full size boat. I also glued the step for the main mast which was a rather fiddly job but came out well centered.

 

 

I also made the breasthook which is notched to accept the two inner clamps.

 

 

I started work on the deck and I thought that if a place a lot of small pieces of tape I would get roughly the shape of the deck. This worked quite well and the fore part of the deck which is the most difficult came out fine.

 

 

 

Hopefully tomorrow I ll finish the deck and install the inner clamp and gunwale and then it will be time for the rigging and fittings.

[vaddoc]

SInce the last post progress slowed almost to a halt due to a number of near disasters.

I first had a serious computer problem and trying to get the system working again I realised all the CAD files that it took me months to create were lost. Then I realised I did not have a back up! Although they have served their purpose I would have hated to lose these. To get the system running again I had to upgrade to Win 10 and thankfully, somehow they reappeared.

 

The second problem was an epoxy one. I bought a new epoxy glue which proved rubbish, either not curing and remaining tacky or curing rubbery with no strength at all. Again, luckily I realised this early but still I had to remove some pieces and scrape and sand to remove the uncured epoxy. I am still waiting for the new epoxy to be delivered.

 

The deck is finished, glued with the rubbish epoxy but still seems to be glued pretty well. I did not expect this to be difficult but actually it took a very long time and a lot of wasted timber to get the deck to fit right.

 

 

 

 

 

Of course, the masts need some wedges to make sure they are snag against the mast partner. There will be some canvas covering the base of the mast and the wedges. (Not really necessary but I saw this in another boat and liked it)

 

 

 

 

 

Since I could not proceed with no epoxy I thought I could work on the rigging. I still am not sure how it should be arranged or even of the rope sizes but I would like to use traditional wooden blocks. I followed mostly the tutorials of Dan Vadas with a few modifications and I think they came out fine. The most difficult think by far was actually the rope work. 

 

 

 

 

 

 

 

 

 

The darker block has a coat of Tung oil which I am not sure is actually needed.

 

I still need to think how the rigging will be arranged and how to make the mast and deck fittings etc. I may need to make some things out of metal which means acquiring new skills or buy them ready. I would like though to scratch build everything if possible.

[Omega1234]

Hi Vaddoc

 

The setbacks can be a real "pain the you know what", but the good thing is that you're well and truly over them. I'm loving what you've done so far, especially your workmanship and attention to detail.

 

Also, I can't leave without saying that those blocks look brilliant.

 

Nicely done!

 

Cheers

 

Patrick

Edited September 11, 2015 by Omega1234

[michael mott]

Hi Vaddoc, just catching up, you have made great progress since I last checked in, and what a superb job you are doing of her. very clever way to shape the spars with the ball race jig and hand drill.

 

Michael

[vaddoc]

Dear Patrick and Michael thank you for your comments and continuing support. Indeed the problems have been sorted, the computer is running fine and the new 30 min epoxy (this Zpoxy brand) is absolutely brilliant. 

 

I fitted the breasthook, the transom brackets and the inner clamp.

 

 

 

 

 

 

A small mistake will be fixed invisible later on, I did not have another strip to make again the part as somehow I managed to use both back up strips

 

 

Next the small blocks were installed between the two clamps to strengthen the structure. This took quite a bit of work as each block was unique to fit each space

 

 

 

Next it was time to fit the gunwales which actually has been so far an easy job. The pattern was easily cut with masking tape and a sharp razor.

 

 

 

Lots of sanding is needed and then the rub rail to be fitted and painted but it already looks nice!

 

 

I started thinking about the oars and also the rudder which will certainly will be a big job. The mast fittings are giving me trouble and more research is needed. Still lots of work left!

[Omega1234]

Hi Vaddoc

 

Damn! She's looking good.

 

Probably not far off now from finishing. Any idea what your next project will be?

 

Cheers

 

Patrick

[vaddoc]

Indeed Patrick, the end is I think in sight. No really sure what the next boat will be, certainly scratch built though. Maybe a nice small fast schooner, the type a smuggler would use but this might be too big a bite. It would also be a 4 year project at least...

 

The gunwales proved to be a mountain to climb and somehow I messed things up. I prepared all the parts and only the simple task of gluing was left and I managed to not align the segments properly. Epoxy is very unforgiving and I could not fix a very small gap at the bow. A shame really as everything was cut just right.

 

 

 

 

 

 

 

 

 

 

Next the rub rails and then the big job of making the rudder

 

[mtaylor]

Nice fix on the bow, Vaddoc.  If you had not mentioned it, we wouldn't have known.  

[mikegerber]

Hi vaddoc

 

It all looks very good! - looks like the real and suddenly, I had still the suspicion that I look at a model, when I discovered the huge drill in the background!   

 

Best regards,

Mike

[Omega1234]

Nice fix on the bow, Vaddoc.  If you had not mentioned it, we wouldn't have known.

 

Hi Vaddoc

 

I agree with Mark. The error is so small, that it's hardly noticeable at all.

 

Mike's also right and I've often had to look twice to confirm that it's not the real boat. Tad Roberts must be really chuffed!

 

Cheers and all the best

 

Patrick

[vaddoc]

Dear all, thank you for the comments and likes. Life commitments again allowed very little work on the boat.

 

I spent a good deal of time studying though and now I have in mind a rough outline of the rigging. I also decided I will make all metal work from scratch, read a bit about soldering and ordered some equipment and metals. There are just a few things that need to be made, the hinges, oarlocks, anchors and spar fittings but it should be a good start to metalwork.

 

The rudder is pretty much ready, needs final assembly, hinges and painting. I also would like to install ropes to lower and raise the rudder blade.

 

 

 

 

 

 

It looks more elegant this way!

 

 

Also, I sanded the edges of the blade.

 

 

I still have not decided on the tiler though.

 

I also worked on the rub rails and here I hit a snug. The two pear wood strips I had saved are not wide enough. I used some lime strips just to have an idea of the fitting, really you can never have enough clamps!

 

 

 

[michael mott]

Great progress Vaddoc, I am sure that you will master the metalwork given the progress you have made so far.

 

Michael

[vaddoc]

Progress is slow but there is definite progress. The soldering equipment arrived and I started experimenting. I will never be able to bent the metal to my will like Michael does but I am happy to report I can now solder two pieces together! These are photos of my first ever attempt in soldering.

 

 

 

I found two suitable strips in my inventory and glued the rub rails in place which was again a rather fiddly job.

 

 

 

I then started work on the mast fittings for the shrouds. The first attempt was not really very nice...

 

 

 

The second time though I think it came out ok. I made fittings for both masts and put a coat of rennaissance wax to protect the shine.

 

 

 

 

I also did more work on the rudder. It still needs painting though. The small hole above the one for the blade axel is for the rope that extends the blade.

 

 

I then decided to have a go at the hinges. I think they look ok!

 

 

 

I also finished painting the rub rails. Much still left to do!

 

[Omega1234]

Hi Vaddoc

 

I reckon you're taking to soldering the metalwork like a duck to water. Another great skill to have that's for sure.

 

Nicely done!

 

Cheers

 

Patrick

[vaddoc]

I think it is time for an update although small actual progress has been achieved. The main thing is that I changed my mind regarding the rigging.

 

I finished painting the rub rails, they came out fine.

 

 

I also made a new tiler as I was not happy with the first attempt. I think it looks better.

 

 

 

I have been thinking about the rigging for a long time and I realised I was not happy with the arrangement I had decided on. I want a more traditional look and to avoid the use of all modern gear like turnbuckles, shackles, wire ropes etc. I also want a accurate representation of the actual rigging. I spent a lot of time researching and I now have a very clear idea of how it will be arranged. The drawing shows the rigging of the main mast:

 

 

The main mast will have one pair of shrouds and a pin rail probably attached to the small deck. The mizzen will have two pair of shrouds and a pin rail attached to the shrouds. 

This means served ropes and deadeyes. So here it goes.

 

I started making the dead eyes which was actually easier than I thought. Lots of little faces watching me!

 

 

 

 

Cutting strips of brass with the knife was easy.

 

 

Tung oil deepens the colour nicely

 

 

And then all came together, soldered and sanded to shape. An easy job although I got carried away and made more than I actually needed.

 

 

 

 

 

 

The dead eyes will be secured to the boat with brass fittings.

 

 

 

There will be need for splicing rope and of course serving. I tried serving by hand and immediately I gave up, this really needs a machine. I tried making a serving jig with whatever I had int he garage but gave up. I will try again though, I think I can make it work.

 

Back to the boat, i prepared and glued in place the brass strip on the false stem which needed a rather complex clamping system. I have left the masking tape on to protect the shine of the brass. I will add later on an eye bolt for the jib.

 

 

 

 

 

Next to paint the rudder and attach the tiler and brass fittings and of course to have another try in making a serving jig. 

[vaddoc]

Dear all, things are going well so I think another quick update is in order.

 

I have all the components for my rope serving machine and will put it together when time will permit but in the meantime I discovered that it is not really needed, at least not for the very large scale rope I am using. In any case, the first attempt in serving and splicing rope was entirely successful. I also think it does not look too bad although I am not sure if the scale is correct.

 

 

 

This is how it will look in the end

 

 

 

I also started making some hoops for the mast. The only suitable strips I had were walnut, I don't think the colour matches the boat very well but with a coat of tung oil it might work. I rolled a wide strip around a dowel and then I glued another strip on top to form a tubular laminate. Then I sawed a slice off and a very nice hoop came out.

 

 

 

I sanded it smooth and then reduced its width.

 

 

 

 

 

Still, the previous mahogany version I think looks better 

 

 

I also am working on the rudder, still needs some more coats of paint and varnish but I think soon it will be time to mount the hinges.

[Omega1234]

Hi Vaddoc

 

I love your attention to detail and commitment to accuracy. Please keep the updates coming, because I really enjoy following along.

 

Cheers and all the best!

 

Patrick

[michael mott]

Nice work on the splice Vaddoc.

 

Michael

[vaddoc]

I managed to do a bit more work so time for another update.

Patrick and Michael thank you for your comments, especially as you are so busy with your wonderful models.

 

I made more hoops, my little method is very fast and works well. 

 

 

 

I also fitted the lower dead eyes for the shrouds

 

 

I did a lot of work on the rudder, I new it would be a complex job but I really had no idea. Fitting the hinges was very fiddly.

It did not came out as good as I would want but good enough. It still needs a lot of work, though!

Interestingly, the epoxy on the middle hinge refused to cure, I suspect there was still some flux from soldering that reacted with the epoxy. I managed to glue it in the end but there is some more work that needs to be done at the lower edge of the hinge to fix things

 

 

 

I also made the oar locks

 

 

I have spent a lot of time searching for an accurate way of attaching the forestay to the stem avoiding a turnbuckle. I finally went for a pair of hearts which indeed is a traditional way of tensioning the forestay. I also made an eye pin for the stem

 

 

Hopefully I ll be able to do some more work this week and at least finish the rudder, the standing rigging, and maybe do some work on the spars 

 

 

Edited November 8, 2015 by vaddoc

[Omega1234]

Nice progress Vaddoc!

[captainbob]

You're moving right along. Fine job.

 

Bob

Edited November 9, 2015 by Cap'n'Bob

[vaddoc]

Despite actually working for many hours, I made only modest progress. I am really struggling with the rigging as I have no idea of how such a boat would be rigged and equipped. I spent a lot of time on the net and also got a lot of help reading the blog of a couple who have been building a sailboat for the last 6 years (a Northsea 29). Still, there are a lot of grey or totally black areas!

 

I made a pattern of the sails. This boat seems to carry a lot of sail, I wonder how fast she would actually be.

 

 

The way I am thinking of rigging the boat, I will need a lot of rope loops. Splicing does work but is very time consuming.

 

 

I also discarded all the ropes from the blocks I had made and re-did them properly.

 

 

It was only after many hours of work on the blocks I realised they were completely the wrong scale. They looked huge on the boat! I tried a few sizes and now they look much better. I also used pear instead of lime wood.

 

I went for the middle size

 

 

The wrong scale is obvious

 

 

I also made the spars. Especially the gaffs needed a bit of 3D thinking as they were carved out of solid blocks of wood

 

 

 

The rudder is almost finished, needs some more brass work, varnish and the blade to be permanently attached with the ropes that will extend and raise it

 

 

 

Although there are lots to be done, I fitted whatever I have prepared to get a feel of the rigging. That main mast top looks a busy place! 

 

 

 

 

 

 

 

I think making some form of rope walk is a must, I would like a better rope than the ones I got from the model shops.

[Omega1234]

Hi Vaddoc

 

I'm like you...I also get totally bamboozled with the rigging.  But, from what I understand, everyone has their own ways of rigging their boat. I guess there's no absolute rule about how these things must be done.  So, as long as it looks about right and it works, who's to say that it's wrong?  Well, that's my excuse anyway!

 

Love your work.

 

Cheers

 

Patrick

Edited November 20, 2015 by Omega1234

[captainbob]

Looking good, Vaddoc.  And yes the mast top always looks busy with the shrouds, stays and halyards all coming together in one place.

 

Bob

[vaddoc]

Thank you Bob, it's good to know that this is how it is supposed to look like!

Patrick, I think you are right, one can choose how to arrange the rigging as long as it works. So lets just have fun!

 

I finished all the spars and fitted the brass components. For the parrel lines I used good quality toothpicks. 

 

 

 

 

I also made some belaying pins. It was very easy to make using dowel secured in a drill and sanded against the rotating disk sander. The rest was done with hand file.

 

 

I varnished the spars with matt enamel varnish to provide some protection. I also added some brass work on the rudder and then varnished the whole thing but this did not go very well. The rudder has caused me much frustration, it proved much more difficult than I though, needed a ton of work and still is not completely ready.

 

 

Finally, I made some more blocks and the pin rail which will be attached on the edge of the fore deck to serve the main mast, where I also intend to install a downhaul for the boom. It is not really needed but then again, why not?

 

 

I intend to make the sails but I have no idea what fabric to use. I would like something resembling a traditional sail but not too thick considering the 1:12 scale. This is going to be a difficult one.