Fitting/Polishing Bronze Knees - Wooden Boat Rebuild (EP82)

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    Rebuilding a historic sailing yacht - Fitting Hanging Knees (EP82)
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    EPISODE 82.
    In this episode, we focus on the fitting, shaping and polishing of the cast bronze Hanging Knees. We cast the last Floor, and production is speeding up in the foundry, with an average of two pieces being made every day!
    Meanwhile, Matt makes THOUSANDS of copper rivets for fastening the hull planking, and Pete fastens more floors into place - taking advantage of different fastening techniques in the areas where bolts cannot be used.
    Rowan returns to the project, and tries - unsuccessfully - to finally make friends with Pancho.
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    Pubblicato il 3 mesi fa


    1. pabstblurobot

      it's like you're building a great cathedral

    2. Mike McCartney

      Wow, those Knees and Floors are spectacular. A lot more expensive, but you'll end up forgetting about the price in the years to come, and just marvel when looking at them. Mike from Australia.

    3. Sailing Cape Dissappointment

      Bright work clear to the keel ! metal polishing is addicting isn't it

    4. Lorrie D Mussett

      Roll that beautiful bronze casting footage!

    5. William T. Musil

      Hiya Leo

    6. crispinleslie

      Has anyone figured out; how many hours per bronze casting from start to shine ?

    7. Michael Ratliff

      this one is a bit of a grind.

    8. Skipp Miller

      You All Do A Hell of a job!!

    9. Gyppor

      I sure hope all those polished bronze parts will be visible when the boat is finished! At least the knees!

    10. Tito Joseph

      I like your Parrot seems to enjoy every step of the boat building plus the music.

    11. Noémie CF

      Watched all 80 episodes in just a week or so, this is amazing work! I knew/know nothing about boats or sailboat and this is crazy!! I was thinking though, any chance you'll do some goody sell like t-shirt or cups to support the project? Fun way to do some advertising and to encourage support! Anyways, love what you guys are doing!

    12. Bryan Michael

      Huge bronze brackets. Crazy amt of bronze

    13. ngoctu2603

      Im gonna build one my own, small one. Thanks so much alot learned.

    14. Jonatc87

      i really find the grinding and fitting and measuring very kathartic.


      Hi from Greece,I d like ask about the weight of 1m3 oak wood you are producing the frames.Is it local wood?

    16. Robert Fulton

      I just want to see the finished product. I’d be willing to bet it’s going to be very cool. I hope he gets some artist to do a bunch of carving on the inside.

    17. Douglas Dexheimer

      Take a look at "Wooden Boat" Magazine, issue 269, for July-August 2019, where there is an article reporting on the rebuilding of "Merln" in Australia. The new Bronze floors appear to be similar to the floors of Tally Ho. In both cases, the original wrought iron "floors and knees" were useless.

    18. Alistair Gmail

      It looks fantasitc just one question who is paying for it? Where does the money come from?

    19. strangetranceoffaith

      Good for you I love what you are doing

    20. Vykintas Simutis

      Greetings from Isles of Scilly waiting for the visit :)

    21. Ed Konstantellis

      Hating that I may be insulting anyone's intelligence Would it not be more easy to fit the wood to the bronze? ....and please pardon any ignorance on my part

    22. Ronald Walton jr

      Like many people, I can't wait for the next episode, so interesting.

    23. Travis Ladegast

      You could probably combine the entire series (at the end) into one complete documentary.

    24. aitaix

      I swear that Leo wears a different jacket for each video. He'll never wear the same one twice. He must have about 900 jackets in the closet.

    25. D|M Photo

      That rivet machine is awesome. Cutting to length on the way up? Less wear and tear on the machine and much faster. Other than working at a sailing club as a teenager I've always worked office jobs, but I wound up doing something very repetitive for a charity day my office did. It was shockingly relaxing and a I really enjoyed it. I'm sure it would get old eventually, but it was really nice for a short time. I would not have minded making those rivets!

    26. Richard Bohling Sr

      The bronze is making the job look beautiful as well as strong. Great to see you went with the bronze instead of iron. Great workmanship everyone.

    27. 28 memco

      My thumbs UP went to the rivet maker.

    28. Peter Mulville

      I’d love to go sailing on her crew will I be tasked with polishing the bronze. It’s beautiful. I think I could do one or two each day.

    29. James & Jennifer Reid

      How long does it take Pete to lace-up his boots every morning? 😜.

    30. Thuita k. Wilson

      Why bronze?

    31. James Smith

      That's a lot of dedication to perfection.

    32. Lococontrol

      Hi Leo I am used to fibreglass yachts but really appreciate the enormous effort and skill you and your team are doing on the wooden Tally Ho keep up the good work

    33. Stu Lora

      Metal work at Sampson's, wood work at Seeker's.... Crazy times.

    34. CanadianRust

      That guy is killing the rivet game. Super productive 👌.

    35. happyhobbyworker

      Did you ever consider to cast with the so called lost form mehtod? this would mean you dont need to build cast forms that have two parts to get your model out. You would protect the wood where your knee shall be with tape and a very thin layer of wax or grease. Then you build a mold of a simple wood structure around the place where the knee will be. You protect the inside of this cavity with a thin layer of wax, put it in place and fill the cavity with polyurethane. Once it hardened, you take the form of polyurethane out and shape the edges and curves until it has the form of the knee you want. You smooth the surface with wax and put this form into your sandbox for casting. Then you can cast your bronce directly into the form, the polyurethane and the wax will burn out immediately and the cavity will be filled. This method should work much faster becasue shaping of the model is very quick and you dont need to take care if it is possible to repopen the cast mold to get the model out. Naturally you have only one go with each form, if it comes out wrong, you need a new model.... Would be interesting to see a try

    36. David Matt

      Happy for you. Beautiful work.

    37. 3D The Duke

      Hey Leo, what ya doin?

    38. Jason Reid

      Approx. many lbs of bronze will you end up using? I ask the question because as a kid there was a big bronze (brass?) propeller in a cove not far from our could see it on the bottom on a good day. It looked to be about a meter wide but hard to judge. I was told it would weigh over 200 kilos.

    39. John Maliskey

      Do you ever Clear Coat the metal???? Inquiring minds want to know .............. just sayin'

    40. Carmel Pule'

      I come from a boatbuilding family and I can trace my forefathers back to 1708 who came to Malta from France. Almost eighty years ago I used to work with my uncle, helping him to build local traditional wooden boats using the same principles as seen in this video, but never as large and voluminous as the one shown in this series of videos. I am well acquainted with the design and structure of such a wooden boat and followed this series of videos with great interest and admiration. All I can say is, I HAVE NEVER SEEN SUCH DEDICATION AND WORKMANSHIP IN SUCH A LARGE WOODEN BOAT, and I just cannot believe the tremendous amount of work that went on in the planning and the use of the best materials and executing the work on such a limited budget. One of those silicon bronze hanging knees is a masterpiece and an artistic sculpture, even when considered on its own. The manner and accuracy in which the keel was placed and how the deck was fitted together with such joints while the bronze fittings, including the hanging knees, needed such long preparation and so much work. Making all the threaded silicon bronze studs and the copper rivets for the planking, is astounding and the dedication of all those who worked on this boat deserves all the praise and respect that they can get for they certainly earnt it. All of the hanging knees and floors/keel/frame metal attachments are a work of art and a masterpiece even as a hewed sculpture when considered as an individual unit. By the time this is launched this boat will turn out to be the best constructed wooden boat that I have ever seen. The bronze and copper work alone is bewildering as far as I am concerned as I have never seen such a selection of " homemade" nonferrous material for a wooden boat. Also, I admired how diverse animals seen in the video seem to join in the human team and atmosphere to provide the occasional sense of humor, especially the strutting parrot which seems to act as a supervisor and inspector of the work. The term, " And what are you doing?" became an expression that when heard, it added suspense as to what answer was expected! I remember visiting and inspecting the Cutty Sark more than fifty years ago in London and that had a diagonal iron structure over the frames and under the planking to stop it from hogging and sagging and twisting. The Victory "Nelson's ship" was also to be admired but I feel that both the Cutty Sark and the Victory did not have the accuracy of jointing, the Silicon Bronze studs, the Floors, and the hanging knees as well made as shown in the " Tally Ho" The base for the mast support is so well thought out. Congratulations once again to all concerned. Note, since that boat will tend to hog and sag when she rides the waves, I would never have cut into the side longitudinals which support the deck beams, as these structural members would need all the strength available in them.

    41. Peter Parsons

      Been following since the beginning,,, Pancho always made me smile, thank you for sharing her with your vidjoe world ! Chickens?...mehh

    42. Micael Håkans

      3000 grit!... Are you shellacking them after? Otherwise isn't it a pain and waste!?

    43. Colin Campbell

      Barring that it looks prity is there a reason why bronze work is polished to mirror finish

    44. Colin Campbell

      When I saw Tallo ho for the first time I could not see that it could be restored, build a new one yes. I don't know anything about boat build. But that's what you've done hardly any of old boat left. You done a wonderful job will be as good as new

    45. Shaggydude

      Leo, I'm glad you didn't try and sand out the imperfections in the floors, it gives them character. Your videos are soooo polished these days, I prefer imperfections to less frequent videos. I did some foundry work in the Navy, our patterns were hard wood, and we used pattern wax for the radius's, sad that it is a dying art.

    46. Ben Roy


    47. rick wilkins

      I am slowly but surely getting Pete's tatts worked out.

    48. snowypirate07

      Those are some sexy and shiny knees ❤️

    49. T. Webner

      You should have offered the shaved off pieces of brass 4 sale to patrons? Perhaps you did?

    50. Human Interfaces

      Understand thé mass weight and physical surface area of bronze in the boat represents an electrical resistivity against thé oak timbers. Hopefully thé connection od all possible Like materials will be bonded and injected subtracted with current for overall balancing potentially. Egen in seawater and in Bertha this fan Gary and the Boat needs to be constantly monitored Aš Ive seen whole propellers disintergrate in Weeks om "Hot" Marinas. The worst ever was Denerau Marina in Fiji owned by Nigel Skeggs where I did and Insurance investigation for MS Amlin. If anyone wants advise in this important speciality font hesitate to contact mě. Hopefully it will help Leoš project. Jeremy (NZ)

    51. Teeuw Nijsse

      Leo, have you ever used cubitron abresive disks from 3M? the really move some material, beter than the standard disks.

    52. Kent Richardson

      Marine repair facility auction:

    53. jessdigs

      Been binge watching after finding this channel. Now I'm caught up. Damnit, better donate to get this project moving

    54. Ross Cleverley

      If anyone from “Traeger” is following this build, how about a nice stainless smoker for Tally Ho. On a gimbal of course! Can’t have a nice brisket go overboard!

    55. Tarman The Champion


    56. Norberto Marcher-Mühle

      from the "worldwide famous" sailing anarchy forums thread ( post #663) "As has been mentioned, once you've gotten the part ground to fit and then sanded to get the sharp edges and corners off, it's not much more work to get it to shiny and it helps keep corrosion at bay. However, having gone to the trouble I'm surprised he's not lacquering them before installation to keep them that way. It's cheap and easy to do, holds up well, and can be re-done when needed without much effort."

    57. Ivan Petrov

      Hi, Leo! Thanks a lot for your videos! You are doing amazing work! Could you please advise some good (or may be even your favourite) maritime book(s) (both fiction and non- fiction)? Greetings from Moscow!)

    58. Jack Trudel

      Now about that electrical socket you keep sticking your finger in, Leo. Does it really promote hair growth? Follically challenged people want to know.

    59. Humblehombre

      Wouldnt it be better to make a portable grinding station up in the mounting area, instead of walking up and down to fit the knees?

    60. William J McCartan

      A question if you would, have you tried using cupped stones for the initial stage of the grinding process to help shape the knees and floors? Or would the cupped stone remove too much material if you were to use one? When I was grinding using a 7 inch cupped stone the frogs on rail switches it proved to be very helpful especially when reshaping the newly welded material back to its original shape. Curious more than anything else. Be well everyone, cheers.

    61. Ted Miles

      Are not you going a little overboard polishing the knees? With as much more yacht to build? Retired Maritime Museum Curator.

    62. randaloo

      How many clamps do you have?

    63. Bill Dyke

      Futtocks! Stumbled on to the floor casting 5 days ago, thought 'that looks interesting', went back to the beginning and here I am. Bereft. Thanks, pal. Fantastic project. Great work, great people, great parrot and whatever happened to Cecca? If you and she are history there's nearly a half million people pissed off...

      1. Bill Dyke

        @on4xb Me too, pal. Narrowboat a bit north of Banbury with a decent amount of internet. Could be worse. Hang in there.

      2. on4xb

        Stuck in the UK (Covid travel ban)

    64. Philip Thompson

      Watching these videos makes me think "What a dumb way to build a boat today!". The floors and hanging knees are so much work with so many frames and such great thicknesses of rare timber. A modern wood composite version of Tally Ho Strip plank or even double diagonal would be much stronger, lighter, many times faster to build and last longer than this version. I am in awe of Leo's talent but can see years disappearing into the void. I have built 4 boats myself, none of this quality, but I can't comprehend how Leo keeps his spirits up at the glacial pace he does with so much work to do still. He is not 1/4 of the way to sailing yet, and he will need superhuman motivation to keep him going where mortals would give up.

      1. Andrew Thody

        @Philip Thompson - Calling it a dumb way to build a boat doesn’t seem to show a lot of respect. Probably all the points you make about modern methods are true but surely they have no relevance to what he is doing. As for worrying about loosing her after all the work that’s gone into her what would be the point of building anything everything in life is precarious. I can’t imagine for one moment Tally Ho is being built as a museum piece more likely sailed hard and enjoyed to the fullest. Nice talking to you.

      2. Philip Thompson

        @Andrew Thody It's not that I don't respect Leo's skill and perseverance - they are both mind blowing. I call this channel "chisel porn" because it is amazing to watch. It is just that some things that take almost no time today, like using composites to join decks and frames, take so, so much work. We have come such a long way today and the old ways are rarely used for good reason, they cost much more, take much more time and are not as strong or watertight. There comes a time in every build when you wonder why you started. I hope that Leo is far from that point but he will need super human reserves of persistence to keep the same build quality up. The boat is so big, the scantlings so massive, the time needed so monumental, it dwarfs one man's ability to make an impact on the project. The effect on his relationships and finances will be stellar. He is lucky to have so many assistants help him with his dream. As for quality - a lesser finished boat can still be a wonderful cruising home, a great voyaging craft and, and this is the bit that worries me, okay to lose. When you cruise a boat you have to know that you could lose her. You try your hardest to keep her safe. But your whole world rests on the security of the anchor or your nav. To lose this boat after all the work involved would be catastrophic. It's hard to cruise a museum piece.

      3. Andrew Thody

        Philip Thompson - What’s dumb about building or restoring a boat the way you want? The guy doesn’t want a modern composite version of Tally Ho he wants to restore her and maybe improve a few bits along the way like bronze instead of steel. It is taking a long time but the quality is pretty outstanding because of this. He seems to me to have a passion for quality and building her as near original as he can. Maybe not the way you would do it but as you say you don’t build quality boats.

    65. terrykilo951

      Preserved Killick would go out of his mind with all the lovely brass that he could polish! Great job gentlemen and ladies.

      1. Jaime Saenz

        "Wittles is up."

    66. ceerw buty

      Must be three years now and, Leo has managed to keep his accent intact. One of his many great achievements.

      1. Christian Koellner

        Accent? He's speaking true blue English!

    67. MULLAC22

      Hi Leo. I hate to be the one to raise a concern BUT somebody has to do it. Way back ( over 3 years ago now ) in episode 2, when Tally Ho arrived in Sequim, there was a comment in the video ( at around 3:38 ) which said " No room to spare " - this was in relation to squeezing the vessel on it's trailer along beside the house to the work site. Given that the current Tally Ho has had all of her frames replaced and will have all sorts of nice new planks, deck rails etc. etc. will she still be able to squeeze back out to freedom when the time comes - as you now have new neighbours with a house etc. any alternative arrangements for exiting the site are becoming severely limited.

    68. ibrahim arli

      No mames ... que Chingoneria....

    69. 84toyota4wd

      Dude you deserve it....

      1. ceerw buty

        6:05 Has anyone told that guy that a parrots beak can sever a human finger?

    70. get some

      LEO, less talk and more work, no offence

    71. Luk

      The new editing is annoying. Cut the awkward interviews and random animal shots, we want to see boat building!

    72. johnod1955

      Aren't all those lovely polished floors going to be in the bilge?

    73. Mark Tahu

      That last rivet should be a gold colour!!! Ask the boys who served on HMS Britannia about that.

    74. James Reilly

      Someone should make a bronze statue of that beautiful bird so it can be mounted in some ,out of the way place, on deck.

    75. James Reilly

      Idea: I’m sure there will be a party to celebrate the launch of TallyHo. There will be many people who will want to see tally ho being launched so have one of your neighbors who owns an area of land near your boat yard and have them open up the field for people who want to come and camp there. I imagine a Glastonbury type scene. The multitudes will come from wide and far. Singing and dancing. Pigs being roasted on spits. One large bonfire in the middle. It would be something for all to look forward to and a fitting send off for Tally Ho, Leo and the crew.

    76. seeni gzty

      Castings are gleeming, lacquer them over to protect the shine..

    77. alain amoretti

      Leo, I am a French man of 61 YO, there is one thing that I wish to tell you, out of the fact that your project, your skills and your dévotion are absolutely amaising, it's that you restore hope in a desesperate world

    78. Roger H

      I really enjoy your content. MUCH better than the boring acorn builders

    79. James Allen

      Looking at this bronze work YOU'VE got to get the foundry to cast a new ships bell for Tally Ho.

      1. seeni gzty

        Suggestion. Saw a vid were an Indian mold maker used co2, to harden the material that looked like sand. This kept the molds from breaking.

    80. SY Sublime

      Leo, Hey Pete! Whatya doin? Pete, Drillin holes in the bottom of your Boat Leo!

    81. Let's see how it goes

      I am mortal again, I just watched every. last. video. on this channel over the last like two weeks. Can't wait to see the lead ballast get prettied up, and can't wait to hear the word "mast"

    82. Henenias

      That cat scream 18:15 !! :D Tally-Ho is coming together nicely with a highly motivated and skilled crew! Because of this project I have decided to buy my friends old midle-engine wooden boat that has great lines and make it seaworthy again. I might even try to restore it :)

    83. Ruben Van der Merwe

      Castings are gleeming, lacquer them over to protect the shine..

    84. user990077

      6:05 Has anyone told that guy that a parrots beak can sever a human finger?

    85. Brendan Hart Might save a bit, love your videos

      1. Brendan Hart

        I really like the industrial safety boots. In the land down under we call them ‘thongs’. Thongs are footwear, not a clothing item.

    86. Ryan Williams

      Next time heat up the brass first before the bending

    87. bilinas mini

      Rowan: the calm voice of a perfect bedtimestoryteller.

    88. foodini

      The daily grind....

    89. Arthur Stoops

      If you haven't already, go see acorns to arabella. They're building a boat from scratch as well

    90. Games4Kross

      I'm kinda confused on why you polish the bronze to a shine, isn't it going to be covered by the internals? If so, wouldn't it be better to just get it to where its flat? Or does making it shine like that have some benefit other than looks?

      1. Mark Hillmann

        Polished surfaces resist corrosion better because there is less surface area to corrode.

    91. Kenneth Johnson

      Leo, Please stop calling your self a boat builder. Guys who make row boats are boat builders. You my friend are a Shipwright.


      I'm pretty sure watching a dancing parrot should be the obligatory cure for grumpiness.

    93. John Payne

      You do realise your efforts and these wonderful videos are keeping many of us sane? This is bigger than the sum of all parts. Tally Ho is already a bright beacon for many. Long may she sail. Grateful.

    94. the merrigans

      Suggestion. Saw a vid were an Indian mold maker used co2, to harden the material that looked like sand. This kept the molds from breaking.

    95. Jeremiah

      I re-watched a couple earlier episodes: Rebuilding Begins and #7. Would you do it again knowing what you know now?

      1. Frederick Stibbert

        There was a moment towards the end of one of the early videos, when Leo realized that the large splits in the original teak keel weren't gonna close up when it got wet again. It's the only point I recall where he seemed worried & a bit downcast. But in the next vid, he bought 2 purpleheart baulks & got stuck in w/ crafting a new keel timber. That unplanned purchase probably took a good portion of his savings, but he didn't moan about it & got on w/ the job.

    96. Nicholas Trado

      would it be wrong to have a bronzed parrot on boat somewhere?

    97. Fredwitrave

      Rowan: the calm voice of a perfect bedtimestoryteller.

    98. Buzz Burman

      "Everybody is getting involved in the grinding." Great bit of editing 8:14 - 8:42!!! LOL Big love for you guys at Sampson, thanks.

    99. Barry Gandersleeve

      I wonder if you varnish or poly the bronze, it will maintain it's bling, at least for a while....

      1. on4xb

        if you look carefully in episode 73 (link with time stamp): you see that while painting the beam shelves, they carefully paint around the bronzen bolts. In my view that means that there wiil be lot of polishing in the future

    100. Woodworking with Andy

      happy to be a contributor