Finishing Casting & Floors / Plank Stock ( TALLY HO EP83)

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    Rebuilding a historic sailing yacht - Finishing Casting & Floors / Plank Stock (EP83)
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    EPISODE 83.
    We have finished casting!
    In this episode, the final lodging knee is cast by Daniel - his first time pouring the molten bronze, and not without a little bit of fire & chaos!
    After a celebration, we work on installing the last of the bronze floors, planing the planking stock, and riveting the first lodging knee into the deck frame of the boat.
    Backtrack, like the rest of us, is unimpressed with yet more grinding.

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    83. Finishing Casting & Floors / Plank Stock ( TALLY HO EP83)

    Pubblicato il 3 mesi fa


    1. cowetaok

      When beating the tops of the rivets why do you use the rounded end of the hammer?

    2. Philip M Crow Sr

      I was thinking that a Palm Nailer, maybe with a little alteration could work on your rivets, nails, and peening...

    3. William T. Musil

      Hiya Leo

    4. crispinleslie

      ‘Tom Sawyers Fence’ Love this project.

    5. crispinleslie

      This project has engaged me almost as much as Breaking Bad.

    6. thomas simonsen

      and there will not come with fingerprints so easily If anyone touches them acid-free white oil is an oil that closes surface Try it really

    7. thomas simonsen

      Here is a really good tip after you have polished the copper pieces on the boat you need to lubricate them in white technical oil it is acid free and they will close the surface so they do not get irritated and the polished surface will last much longer. a wide technical oil just looks like water is a little thicker but it is really good if you can lubricate it on a hot summer day to let it sit as long as possible so the surface is saturated and if they dry out Give them one more time e It is especially good when it is molded material and the nice surface will keep me longer Sincerely, Thomas

    8. Zac vaper

      How will you protect the floors...wax?

    9. lord Powell

      I dont know anything about rivets but it looks like there's not much actually catching after its hammered out the head needs to be bigger? Idk its probably fine i was just looking at them and thought they would pull through relatively easy idk could have just been the angle tho

    10. JagLite48

      I'm loving the build and informative videos. Reminds me of the story about Great Grandfather's axe passed down through the generations. The handle has been replaced 7 times and the head 3 times but nothing cuts better than Great Grandfathers axe... Tally Ho rebuild and restoration...? New keel, stem, and stern timbers New frames and floors New deck beams and knees New planking New deck New cabin New spars..... Is anything of the original boat going to remain on the new Tally Ho? This is the best way to do it though, leaving really old timber in can be an endless source of problems. But, this is not a restoration, it is a recreation of the original boat. Bravo!

    11. marcin surowiecki

      Leo yoy need moonwood for planking

    12. John barfneck

      18:34 wheres his bike at.........?

    13. MikeCharlieAlpha

      Should be a new one today right?

    14. Joe B.

      I haven't seen your videos since you cast your keel. Nice job man you've come a long way!

    15. Andy Aim

      The USS Constitution used live oak in its construction and the British cannon balls bounced off her sides giving her the nickname “Ironsides” 😊

    16. Arlen Margolin

      Well it was kind of shocking to hear Leo mention something about future owners of the boat and kind of shocked me like I said that anyway it is kind of shocking that Leo is thinking about anyone owning that boat but him

    17. Arlen Margolin

      Does anybody know the purpose for such a such an expensive bronze casting and such a labor intensive one at that

      1. Frederick Stibbert

        Leo decided to eliminate any iron or steel from the structure of the boat. Iron ions weaken wood fibers (iron sickness), then the wood rots more quickly. Bronze & copper don't affect the wood as much as iron.

    18. Don Devine

      A thing of beauty is a joy forever

    19. Riccardo Bossi

      Finally caught up, it's been a nice three day long marathon, this project is amazing


      Maybe Leo's hair is all cowlicks and CAN'T be tamed!



    22. john k mcgregor

      How are doing haven’t seen you for a while except popping up on from Acorn to Arabella. How is the Tally Ho faring. 🏴󠁧󠁢󠁳󠁣󠁴󠁿

      1. on4xb

        You only have to go back on previous videos and you will know everything... there are 83 of them and every two weeks a new one is published


      Congratulations - however - the champagne cork in the water wasn't OK (confident you'll do better next time). Carry on...

    24. tomatoking001

      Hi Leo, Just found your channel last week and has just finished bing watching all 83 episodes and looking forward to the next. Very enjoyable and informative, thank you. Best channel on IThomes!

    25. Lachy Dachy

      Imagine it just sinks after all this work, lol

    26. Bert Vermeer

      I'm hooked! Just came across this channel a couple of weeks ago and caught up! What a great project with just the right guy to undertake it! I've worked on many boats over the years but intimidated by the wooden ones. And now I can see why! An incredible amount of knowledge and skill needed to rebuild something like this! Good for you! I'd love to come down from Victoria BC for a couple of weeks, but that isn't possible......

    27. rossmaynard

      I've just binged watched every video... your craftsmanship is incredible. It makes some great boat builds look amateur in comparison. Your design choices are spot on... but there must be a better way to rivet the knees on... don't damage that finish you worked so hard on! I cannot wait to see this finished and on the water, but I will enjoy every video that gets you there! Keep up the great work!

    28. Serban Oprescu

      My advice is to forget about aesthetics and put the washers, too.

    29. Ronald Walton jr

      Anxiety is eating me up. When do you put the motor in or start searching for a mast & spars?

      1. Ronald Walton jr

        @on4xb Thank you, just so exciting.

      2. on4xb

        A bit impatient ? There are a few things that have happen before engine and mast come around: all the planking, deck, electricity, water, grey water and fuel tanks, interior, fittings.... At least two (rolling) years

    30. john williams

      copper is annealed by heating and quenching in water !


      Finally finished the Bronze - Bravo - heres some old school boats to keep you pepped up and inspired to go the nex leg you old sea dogs -maybe spot tally Ho BiTDay

    32. Tom Foskett

      Palm nailer with some attachment would probably making peening faster and easier in tight spots. Also a nice noise for the neighbours

    33. Ken Shores

      Leo: Tally Ho is looking really good. Great video.

    34. willy mueller

      How much did you pay for all these floors ?

    35. My Tech ID

      the people who built this boat with their labor should own the boat

      1. on4xb

        Leo is always busy with building, so what is your point ?

    36. TJ

      To hold your main rivet, make a thick rectangular metal template that has a relief the same size as your pre-formed rivet heads, and make the metal long enough to be C-clamped around the beam. The relief will index on your rivet and the C-Clamps will hold it all against the workpiece. Once that's sorted you want to use a rivet "set" (looks like a punch, but instead of a spike it has a concave) that's the proper size for the rivet head you want, for a really large head you might use multiple "sets" as your draw the head out. With the use of a set, mistrikes on the finished knees should be a thing of the past. The issue of space to actually hammer the set could be solved by using an air-pneumatic hammer (like a palm-nailer as another commenter has mentioned). You could also use a hand anvil (dolly) or make your own. Cut a 5lb steel hex dumbell in half, and use it in a "hammer fist" clubbing motion (like you would bang on a door with the side of your hand by your pinkie finger) to peen the end over. The added weight allows you to work the rivet. This is obviously more physically strenuous but gets the job done. You could grab a 5lb hand sledge by the head and try this out first to see if it'll work for you before buying/making any special tools.

    37. massimo zerbini

      sampson boat co una pettinata alla tua folta criniera ogni tanto farebbe bene che ne dici?

    38. Michael Morgan

      How come the rivet's aren't made as a bolt and screwed up, as opposed to been peened over.

    39. Tom Hman

      The tally homer is coming along.

    40. Joshua Frost

      Those rivets are driving me bonkers. Much too weak for the application because there’s not enough of a head on them. The amount of shaft that should be protruding from the jig should measure 1.5x the diameter of the shaft material.

    41. Jacob Herron

      Loved it I also enjoy watching all your videos go Tally Ho


      Why on Earth would you hammer the rivets by hand and damage the knees when they're fully visible when you can use a little bit of heat and a pneumatic hammer and get a beautiful rivet head with no "idiot" marks on the knees themselves.

    43. John Jamieson

      It doesn't get any better than this...

    44. Kuhilani Suganuma

      I cant wait to binge the whole build when this is finished

      1. on4xb

        An another two (rolling) years ... you are a patient man

    45. Lucas Rudd

      Your oxy cutting is very bad. Better off just cutting with grinder disk.

    46. Theophilus Jedediah

      What happened to the river maker? It seems that could be adapted to make the longer rivets then those could have a hammered look after the head was made.

      1. on4xb

        the rivetmaker is for copper rivets, these are bronze rivets and much harder.

    47. Les Chortos

      Who is paying for this project. Its gotta cost millions.

      1. on4xb

        That question is answered at the end of EVERY episode !

    48. Les Chortos

      Who is paying for this project. Its gotta cost millions.

    49. Klaus the German

      Finally caught up with the videos. Your project is most helpful to keep me entertained during quarantine. I wish I could come over and volunteer, too bad that's not an option rn.

    50. simon phillips

      When you look down at 17.55 the scale lets you see that, those are proper planks.

    51. Walker Smith

      You should make T-shirts and sell them if you don't already.

    52. get some


    53. blinkinbaboonbiskit

      Leo.... eye protection....

    54. gearmo B

      As always, enjoyed the craftsmanship presented. A "bucking hammer" is a pneumatic tool designed for setting rivets. Once to be used to build bridges, still widely used in the aircraft industry. Very fast and precise. Similar to what is used by auto mechanics. When cutting steel, I would clamp a length of1 1/2" steel angle to guide the cutter head. A smaller cutting tip ( 00 I think) angled slightly forward to "lead" the cut results in a very fast and accurate cut with minimal slag and greatly reduced clean up.

    55. Ken Wood

      I’ve watched this one 3 times! I can’t get over the quality. Just amazing 😉

    56. Mike V

      I'm glad I'm not the only one that hammers in drill bits....

    57. byrysh

      Well Leo. Since so much of the boat has been replaced shouldn't you rename it "tally who?" Lol it's been a pleasure watching you and Doug!

    58. Zardwark

      The sun beats down like a hammer from the featureless sky onto the featureless ground. No water. No life. Nothing. The desert between episodes of Tally Ho. Nine days to go.

    59. Midnike

      Leo, why you don't use a rivet set for riveting and making rivet heads?

    60. Chris Foote

      One late breaking thought would be to cast a ships bell. I don’t know if pilot cutters had ships bells or not. Great series !! Thank you.

    61. freemanjack msiradio

      @Samson Boat Co Not a criticism, i did the self same, your welding gas and heat from the arc want to be aimed into the joint to be welded, I have seen you mig a few times now back (or kack) handed, this means your shroud gas is aimed away from the work as is your heat. The gas passing over and through the welding arc is both flux/oxygen exclusion and scouring agent to clean the next bit of weld. Esp on thick pieces you will get far better penetration and fewer incursions if you weld conventional, gas and wire aimed into the joint to be welded. ps. don't trust the parrot, its plans are just on hold while bill and melinda try for world dominance!

    62. Educated Guess Works

      Simply brilliant, love the team work!

    63. Paul Haynes

      Only just clicked that there was some (very) brief drone footage in there! Have I just not noticed it before, or was that the first time?

      1. Paul Haynes

        @on4xb cheers, obviously too wrapped up in the rebuild to notice!

      2. on4xb

        There has been drone footage in earlier videos: for instance episode 55: (the regatta in the bay) and in the same episode at 18.11 when they load the planks in the kiln. This list is not complete, there are more drone shots

    64. huskyneusify

      You might find a pneumatic jackhammer usefull, the kind they used to rivet steel beams together. They come in quite compact sizes too.

    65. Bob H

      Thank you Pete and Cathy at the Port Townsend Foundry for all your help. Amazing dedication to your project Leo and team, keep it up.

    66. Peter Halstead

      Why polish all the bronze when it will soon tarnish

    67. Vee Dragon

      Tally Ho!

    68. Tom O

      not wearing the seat belt in the forklift at all

    69. John barfneck

      ?what do you toast with if you dont drink alcohol

    70. Tio Patinhas

      With each episode I'm more surprised by the amount of work ... Congratulations, team.

    71. drail80s

      Wow! Lots of Passion. Would it be possible to get some scrap pieces of Purple Heart?

    72. Reaper 200559

      After you finish this boat could you try and make a replica of the USS Constitution.

    73. Scott Tuttle

      Can you explain the tar paper between the floors and keel / frames? If I remember correctly the tar paper was used on the keel joints to maintain spacing so the bedding compound did not all get squeezed out. Did I miss bedding the compound going in? It looked like just the red lead paint.

    74. Patrick Connors

      Dude looks like Wyatt Ramsey.

    75. SteegZor

      Why don't you bolt the floors to the frames?

      1. on4xb

        They will when the planks go on, all 3 parts with one copper rivet per fastening

    76. Steve Fletcher

      You need to get an air hammer with a concave end to hammer the rivets, see old videos re steel shipbuilding the difference is,they were red hot!

      1. on4xb

        Yo cannot do red hot with a wooden frame/deck beam.

    77. Tim Gay

      Leo, are they covered with a coating or varnished at all as we all know metal tarnishes over time or will you have some crewmember polishing it now and then as with brass work etc..?? haha at "Leo's dodgy driving school" Here in Australia you are not allowed to drive a forklift of any kind unless you have done a proper course and have a plastic card provided by WorkSafe stating "License to perform high risk work" with all your details and a lovely mug shot (selfie) of you so they can see it really is you causing an issue haha... I also noticed that when you were Peening the heads of the rivets there were a number of (what I was taught by my grandfather) "2 bobs" hammerhead marks on the knee that you put in place at the hatch. This was a kind of fine that the old-timers would use to help you be more careful when hitting the rivet and not the area around the rivet, it would cost you 2 bob (20 cents equivalent these days) and that would be put into a jar and spent on other things needed or drinks paid for by you haha.. maybe this is something you could also do there. She is coming together quite nicely and you will not know yourself soon as she will finally start looking more and more like a boat with the planks and inner sections appearing. Great work to all of you and thanks for the video each week, I look forward to seeing this every week.

    78. Sudo Penguin

      Maybe if you post more videos you’ll have less budget restraints..

      1. on4xb

        and much less time to build TH, The videos were always produced on a two scheme

    79. David Aitchison

      Unfortunately, Tally Ho will always be 2 years from her launch date. IThomes has no more videos of this wonderful project. I really was hoping to see her in the water.

      1. on4xb

        Eventually she will be launched "two years in advance of the schedule" . (This is an authentic statement from Leo).

    80. Thedevontree

      Did you get a real roof or is it still that flappy plastic

    81. Daniel Syverstad

      I might of missed it, but anyone with experience answer me this... Once cast, do you reuse the sand or is it toasted?

      1. Daniel Syverstad

        @Frederick Stibbert Thank you!

      2. Frederick Stibbert

        The sand (olivine) is a volcanic mineral & is re-used. It's run through a muller to break up any clumps.

    82. Bob Eden

      green sand and parting powder, what more could you ask for, hey?

    83. Wayne G

      Leo needs to Patent/copyright, whatever, his hair style! He must use some sort of shipbuilders gel/tar in it. Great vid. Shivered my timbers.

    84. Birashanuman

      It is impossible to follow this series of enthralling and consummate episodes without drawing parallels with the restoration and reconstructions of Edwardian (Am. Brass era )automobiles of the same era ,with its emphasis and intricacies of high-end craftsmanship, attention to every detail, superb carpentry and casting procedures, and veneration of pioneering achievements of the early 20th century. Belated congrats on what is probably one of the best series on IThomes .

    85. Norman Merrill

      Great workmanship attention to detail...

    86. Terrance Roff

      That bird is a serious super star.. and he/she knows it! Lovely bit of work there gents and gals. this is going to be one of those boats that looks at hurricanes and goes "save my beer I'll right back.. need a little wash off!" the strength in that hull is going to be phenomenal! And lets toss in it's likely that few teams have ever put such deep care into the building of a ship. The love of what you doing is visible and real. And love it what will keep her afloat when all else is gone.

    87. Phil Saunter

      I don't know if it's powerful enough but maybe try a palm nailer for those tight spaces between the beams.

    88. daedster1

      Guys, what are you using to stop those knees going green during the build?

      1. on4xb

        @Frederick Stibbert or polish them regularly

      2. Frederick Stibbert

        Leo hasn't mentioned any coatings, I assume he'll just let them tarnish..

    89. paul brautigam

      I think I remember seeing these mini pneumatic air hammers. I bet one of those would help a ton with the rivets in those tight spaces

    90. Hartwig Grünewaldt

      Wonderful documentation of wooden boat building! It is so nice and interesting, to be able to observe and to see all details of all work steps. But there is one question for me: Between the fittings and the wood you put first red lead putty (to avoid rot in the wooden parts) and then, there is a "black paper" like roofing felt. What a kind of "black paper" is it and what does it prevent? Thanks!

      1. Frederick Stibbert

        That stuff is 'tar paper' or 'roofing felt' - bitumen-impregnated wood fiber. As the planks are riveted, the felt will get squeezed around to fill any gaps between floor & frame, eliminating pockets that might fill w/ water. To me, it will degrade the performance of the joint, which depends on friction between bronze & wood. To Leo, it's more impotant to eliminate potential rot pockets. Gonna have to go w/ his informed expertise here.

    91. No fox given


      1. on4xb

        @No fox given He did on instagram:

      2. No fox given

        @on4xb yes i thought about that but leo never even talkes about her you would think that since they are an item he would have menshioned her in one of the videos but he dosent not one.

      3. on4xb

        If you think about that for one second, you will know ! At the moment we live in strange times: she's stuck in the UK (Covid travel ban)

    92. Andrew Rae

      Hi Leo, are you going to get New Original Hemp Ropes from The Ropery at Clapham London for the Rigging ?

    93. Michael Wooda

      I would be using an air hammer to peen those brass more uniform and tons easier.

    94. RHP9898

      Is it my eyes or was a lot of the video out of focus?

    95. John Manning


    96. William J McCartan

      I'm not sure but maybe a battery powered auto hammer might work in the limited space, floors look great, cheers

    97. econchino

      4:29 how much product is he using in his hair?

    98. chalo colina

      At what point are you more a historical reenactor than a shipwright? Building a boat out of compostable material rather than composite or metal may seem, you know, cute... but the real thing would be seaworthy much longer, no? (I hate working with fiber/resin composite, but I know I'd rather sleep in that kind of boat.) Wood is awesome material for many purposes, but sitting it in water all the time isn't really one of those purposes.

      1. on4xb

        Wood loves to sit in (salt) water and if maintained well goes a very very long way ... Nearly every part can be exchanded "easily" when damaged. TH was not maintained (one could even say that it was abused) in it's later life (from the '60ties onwards). Thats the reason why it turned into a restore/rebuild. There are still many 100-150 year old ships sailing the world. TH, when launched is ready for at least another 100 years, try that to achieve in a fiberglassed tub.

    99. Dwayne Koblitz

      She’s really going to be a spectacular boat!

    100. Redsamme

      Has the bird picked up any shop noises or sayings? I know not all parrots are talkative but it'd be interesting to see more of him lol