Metal work

Work continues on the bronze sheaves (pronounced “shivs” by the way) that will guide the rudder cables.


On the left are two sheaves that haven’t been grooved yet. Dean used a bowl cutter shaped bit on the Bridgeport milling machine to cut this groove. It’s the gold-colored bit in this photo.

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He mounted the sheave on fixture that allows him to turn it precisely. As the sheave turns on its axis, he moves it into the spinning cutter.


He could turn the sheave by hand, but it’s easier to use a drill to provide steady, constant turning.

It’s handy to have a guard to keep all those metal shavings from flying out at you.


The volunteers have been making a lot of sea chests for the Morgan over the past year. I’ll have photos of these soon. They are doing all of the metal work for the chests as well as the woodwork. Here is what the hinge looks like before being folded to accept a pin.


Jack is shaping the stock after heating it in the forge.

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Ali uses a file to refine the heart shape.


Here are the hinge components after bending for the pins.


Mike and Ali have been working on pins for the chain plates as well. This is the part that they were shaping in the video at the end of the last blog entry. The pins will eventually go here:


The upper pins have been installed, and the lowers are what Mike and Ali are working on now. Mike starts by rounding over the end of a substantial steel rod.

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He then heats the end until it’s hot enough for he and Ali to work it.


They put the rod through a plate that’s sized for the rod. As the top of the rod is hammered, a head is formed down onto the shoulder of the plate.

A little more heat, a little fine tuning,


and they end up looking like this.


There’s lots more metal work to be done. Here’s a sample of some of the recent projects.


Earrings, or hound rings, for the ends of the yards. They look like this when installed.


There are also twisted metal rings that go on the ends of some of the earrings. You can see one on the left in the photo above. Mike makes these as well.

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Over in the main shop, the fore t’gallent yard shaping is finished. You may recall that this is the spar that came out of a larger, warped, yard.


It’s now straight and smooth.

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After planing with both flat and curved planes, we use a 3-sided sanding box to do the final rounding.


Next, we’ll take a look at what the riggers have been up to.  For now, it’s time to heat up some soup and get out of the cold.