BoatBuilding - Casting Bronze Floors (EP75)

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    Rebuilding a historic sailing yacht - Casting Bronze Floors (EP75)
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    EPISODE 75.
    In this extra-length episode, Pete and Clark show the process of making individual patterns for each of the floors, laminating thin strips of ply into the boat and then shaping and sculpting them into the shape that we need. Patrick returns to help get the boat ready for planking, and we take the patterns to Port Townsend Foundry, where we learn all about the exciting bronze casting process, pack some moulds, and pour the first two floors for Tally Ho. When the molten bronze has solidified and cooled, we can break them out, grind them down, and take them back to the boat to see if they fit! Meanwhile, Pancho keeps her beady eye on the hens, and Backtrack expands his repertoire of napping spots!
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    Music;
    TrackTribe - Delta
    Slynk & Mr Stabalina - The Jam
    The Mini Vandals - The Shepherd
    Text Me Records / Grandbankss - Realism
    TrackTribe - 1968
    The Mini Vandals - Sam the Man
    Freedom Trail Studio - Dwarf Star
    TrackTribe - Dance 4x

    74. BoatBuilding - Casting Bronze Floors (TALLY HO EP75)

    Pubblicato il 6 mesi fa

    Commenti

    1. Old Iron Shops

      i do a bit of pattern making as a hobby and its very under rated what it takes to get a good part out of a mold.

    2. Bryn Chamberlain

      She's looking great Leo & Co.

    3. Tim Yonker

      Fine the term “fair” and “fairing”. Give us some synonyms.

    4. Mister Bee

      I try to imagine ancient boat builders with a new design..how they did a shake down cruise to determine center of gravity and how much ballast they'd need, how much sail thru could fly, how big a rudder they needed, and all the other things you want to meet to figure out with a new boat design. Now we've got 3D design with onboard strength of materials so they can..with the click of a mouse determine, for example, how thick a certain piece of metal needs to be, how strong the standing rigging needs to be, etc. Watching you guys work is inspiring! What an awesome project, and what a boat you'll have when you're done!

    5. Mister Bee

      Boat builders from years gone by would've killed for those clamps! And the electric saws, and being able to go to a store and buy gallons of glue and fiberglass and sandpaper and advanced sail materials, stainless steel anything, etc.....you get the idea! That being said..written..it's still quite a tall order to build a boat like you're doing! Can't wait to see her sail!

    6. Mister Bee

      That is the coolest band saw I've ever seen! Is that boat building specific? If anyone wonders why boat terminology is so bizarre here's the answer...I think. If I'm wrong, please let me know. I've been sailing since I was 5, I windsurf also..no kite boarding, yet! I've read about sailboats, I've researched square rig brigs, galleons, schooners, etc war tactics, I just love learning about sailboats. I believe all the strange terminology is because sailboats have been around for about 7000 years and names of things in boats came from all around the world.

    7. Scott Pecora

      Regarding the extra expense of using bronze floor brackets. It's like buying tools. You've got the cheap one, and yeah it sorta works then there's the quality tool. It gets the job done, but with a certain finesse, and ten years later you reach in the drawer for it you no longer remember what you paid, you're just glad you bought the quality one. Some day you're going to be in some big ass swell you hadn't planned on. At that moment you're going to mumble to yourself, "God I'm glad I went to that extra expense right now, because in her heart I know she's built solid!" I've never met anyone who regretted going to the extra expense on something, saying; "I really wish I had just gone the cheaper route!" Looking really good

    8. Ben Hart

      Hey Leo! What do you plan to do with the floor forms when finished? They would make great furniture!

    9. Daniel Clint

      Nothing but respect for you all.

    10. TheSilversheeps

      How did you cope with the pattern contraction and distortion at 1/70? -No worries see it at 14:00 time mark...

    11. Zer0

      Tell Pete to stop eating that packet of crisps at 41:49 I can see how it is distracting you

    12. resa xasd

      This is one of the coolest episodes of probably the best series on IThomes. Thank you for this.

    13. kssarh

      This is such a great video. I'd love to know the final cost. I'm kind of stunned the raw materials are $11K with copper at $2.60 a pound when this video was made. Is that really 2 tons of copper!? I was also surprised how labor intensive the process is. I'd figure it was at least 40 hours of labor to make that first mold. That'd put labor costs above material costs unless they were able to dramatically shave that time down as they went along.

    14. GARY STOPKA

      Awesome job to you and your crew . Love your videos

    15. Mr,Willson

      Boggles my mind....WOW !

    16. Peter Bryce

      Beautiful!

    17. Andrew Mason

      THE INTRO IS BACK YESS

    18. Sir Dr. Michael Mills, Phd. Esq.

      All these non building fools commemting..leo perfect..ect..dick riders..this boat is way over engineered..unless you are hauling munitions. Or sailingthe artic, thos ship would kever ever need to be this strong., bronze hidden floors...look amazing? No one will ever see them...you wasted all these ppls money

    19. ick5353

      Who else thinks that Clark looks like a young Ron Swanson?!

    20. Andrew Seaman

      Really wonderful to watch this beautiful yacht starting to live again. A simple question: why don't you cut the floors from a bronze sheet and attach two of them to a beam, one from the front and one from behind? That is a traditional way of building and you'd save both time and cost without sacrificing stability. As for varnishing the wood: a traditional way of conserving wood was to use oil which is absorbed by the wood and preserves it from the inside, lets it breathe and dry - unlike varnish which creates a coat on top that starts to degrade sooner than later and which keeps the wood wet and prone to rot underneath. If you use wood tar as an additive to raw linseed oil you won't have to bother ever about rot. Working with oil allows you to add a new layer anytime without removing the old.

    21. Stephen Charles

      I hope the Gorilla glue comes sponsored!

    22. Stephen Charles

      Respect....

    23. Richard Finney

      Why in gods name are you using gorilla glue every wood boat ive seen built has had system 3 epoxy used in the joints and joining also on the decks along with 3m 5200 ureathane for under the deck cleats and anything thats fastined down on deck is boeing uses it its good enuf for a yacht im in lynnwood wa i would love to come over and help im an old hand at boats my dad had a boat shop in lynnwood in the early 50s i worked in alaska in the 70s and 80s

    24. Richey Rich

      At 1:40 a young Ron Swanson appears.

    25. Bill Dyke

      Wow! They've been casting bronze for thousands of years and it's still done the same way. Bring back the Bronze Age...

    26. Paul McGee

      Gotta say, what an awesome contribution by the guys to the project. Big praise.

      1. Paul McGee

        PS it's great that they could get Nick Offerman to do all that work. 😛

    27. Paul McGee

      "While Leo's been having coffee". Hahaha. Winning. 🤣

    28. t44warrior

      Wow, the bronze is looking so good.

    29. Nelly Nell

      Your bird is sharpening a prison shank... better make sure to give him your fruit at lunch time or he might catch you in the yard later... 😂 Awesome boat

    30. Simon Hawker

      lamination lamentations

    31. Simon Hawker

      boat builder dont you mean shipwright?

    32. killi mimes

      Bronze is ok, but the U.S. Navy uses MONEL and Inconel for corrosion resistance.

    33. spencer churchill

      Leo is such a sweet heart

    34. Richard Anderson

      I built a small foundry for some casting I wanted to do and the learning curve is as steep as it gets. Molten metal forgives zero mistakes and a steam explosion is no fun at all.

    35. Mountain Man

      Everyone's hair is funked...

    36. Mountain Man

      The music sucks. Should be Bach or Beethoven...You're building a boat, not a NASCAR engine

    37. Dario Martin Lobos

      OTHER PROBLEM ARE THE BOLTS IN MY OPINION OUSIDE THE FRONT DECK AND KEEL ZONE HAVE TO HAVE A STAIN LESS STEEL SHEET METAL PASTED WITH EXPOXY RESIN (APPART OF BIG WASHERS). THE BOLD MOUNTED AND SEALED. IF DONT THE BOLT DONT HAVE STRONG SURFACE TO TIGHT THE STRUCTURE AND THE METAL REINFORCEMENT WITH SOME TIME DONT DO ITS FUNCTION AND ONLY WORK THE WOOD ALONG. SOME SCREWS CAN BE WOOD SCREWS LIKE THIS www.tuandco.com/media/catalog/product/cache/1/image/451x455/9df78eab33525d08d6e5fb8d27136e95/t/o/tornillo-madera-ehs_1.jpg IT ALWAYS WORK OVER THE WOOD, BUT WITH LESS TORQUE.

    38. Dario Martin Lobos

      IF YOU LET ME DECIDE A GOOD AND CHEEP MATERIAL I WOULD USE TRUCK OR TRAIN SPRINGS RECICLED ARE STAIN LESS STEEL www.truckid.com/images/semi-truck/pages/leaf-springs/top-gallery/heavy-duty-replacement-leaf-spring.jpg iT CAN BE DONE SOMETHING SIMILAR FORGED RECICLYNG. DID YOU CHECK IN ONE PIECE WITH ANY TEST LIKE CHARPI OR WITH A SLEDGE HAMMER? THIS PART ARE STRUCTURALS TO GIVE YOU AND EXCAMPLE THE STRUCTURAL PARTS IN A CAR LIKE WHEEL AXIS ARE TEXTED 100 PER CENT OF THE PRODUCTION.

    39. Dario Martin Lobos

      is interesting the casting. but In my opinion always the laminated bronze have more strength. You can cast but after that you must be sure with penetrant ink that no have cracks, the same procedure as an aluminum alloy wheel. Like cranckshaft or knifes (ithomes.info/net/nb2u1JFrsJp1gWU/video) always to improve the strengh properties need knocks. The laminated brass (or naval steel or naval stainless steel) already have the structure (fiber) of the metal aligned. Always needs to be checked from crack free after bend. Also for one time molds you can use plaster, wax, or plastic.And you can use silicone molds to make wax molds and then hot the wax to have a precise piece in one part mold. And including this you can do bigger plaster molds to make one set of cast aluminum originals and work in it for improves. Other material that I used more than 20 year ago to develop a cylinder head is a mix with soil, oil and sulphur to modify the mold in an original. To give you an example to fill an cavitated propeller and change the shape. Is the old material used in car factories to modify parts from an already casted original. I hope this can help you in your work.

    40. Mike Ivy

      What a wonderful video. I am allowed a peak into the building of a beautiful Yacht. What talented craftsman involved. Thank you all for the demonstration.

    41. Martin King

      Not sure what good a hard hat is going to do and yet you're not wearing a face shield or any lower body protection which is the areas most as risk.

    42. K. W. Churchill

      No safety glasses?

    43. IanCaine4728

      This video is awesome! Thanks to everyone for the full explanations and not "dumbing down" anything. Fantastic and fascinating!

    44. Teri and TL Stanbro

      Beautiful work

    45. David Lindquist

      I have 500 pounds of lead I could donate to the cause.

      1. Sampson Boat Co

        Hi David, thank you for the offer! Could you send me an email at info@sampsonboat.co.uk ? Thanks again!

    46. IcyMidnight

      Pete loves to tell us what he's doing!

      1. IcyMidnight

        Also he knows too many words for various kinds of angled things 😝

    47. Damon Teague

      Great video!

    48. Patrick Hayes

      Might you be leaving a camera and light down in the hold so people can see the floors in place? They are so beautiful, it is a shame to think they will be down in the dark!

    49. whotknots

      The rough surface on basically untreated castings probably increases their surface area by a larger margin than you might think, that would probably facilitate a greater degree of surface oxidation/corrosion.

    50. RG

      this has given me a whole new perspective on carbon fiber

    51. Nicholas Michael

      So these guys are the reason i can never find clamps in stock at harbor freight...

    52. UltraMegaton

      I wonder if the next time they need replacing, they’ll be 3D printed?

    53. scheusselmensch

      Since you're obviously accomplished carpenters could you not make custom pour boxes that would cut down the volume of sand required dramatically and the tendency for the sand to compress.

    54. Randy Leifer

      As a specialty paint finisher... it's nice to see the elaborate casting process. I often receive a cast bronze/brass object(s) to paint/finish.... and sometimes I forget about the object's life, before it's put into my hands.

    55. Randy Leifer

      "Lazy Dog Boat Company"

    56. scheusselmensch

      No eye protection on that second pour? You need yer head examined.

    57. Exidy YT

      Covid boredom is leading me to some very strange, but totally fascinating places. :-) I love metal casting, and I love the Age of Sail, looks like a win/win video and perhaps channel for me!

    58. cold spring

      Beautiful

    59. zechariah smith

      Anyone else notice the oxyfuel torch leaking at at the tip? That's definitely how you get blown up if your flashback arrestors arent in good order.

    60. arty Berkhoff

      Those drain holes seem awful small.

    61. Ed Medlin

      Proud of you, good work man! Sure, it is more cost to use the bronze and the end product will last longer than we will and you will have the pride in a job well done for the rest of your life. I am a retired marine engineer (not naval architect !) and have a particular love for ships and boats, and this one really touches my heart.

    62. Gregory Gagnon

      This series is totally awesome.👍

    63. Matt McG

      Clark is a natural presenter. I could see him easily front a DIY show of his own. Good stuff.

    64. scott left

      Parrot leaning to be a ships carpentor...lol.

    65. ilias Alexiou

      GREECE 💙 👍 🌳💒🌳⛪✔

    66. Antryg Revok

      I don't understand why the template thingies aren't coated with composites mold-release wax, as it'd make for cleaner sand-release, & therefore less grinding, later... Also, what angle do youse need on the template to be able to part the halves without trouble? 3 degrees? less? more? ( :

    67. R Riquelmy

      See a speech therapist please

      1. Sampson Boat Co

        I’d settle for a regular therapist to be honest.

    68. Charles

      In regard to the Limber holes, for draining water. the transition created causes a stress concentration that may, or may not be significant. It is better to transition the profile thickness gradually so in this case it is better to make the holes convex instead of concave. That is the outside corner should be a curve following the inside curve to maintain a constant thickness that Changes gradually, especially at the point of maximum stress. great work on the boat.

    69. CHIP FRIDAY

      Child, where was your eye protection/ goggles? Don't you forget that metal will splash just like water.

    70. Stelios Posantzis

      Amazing. I sure hope the boat will last for more than a century or two. Can you stamp a date on them? or is that a no-no?

    71. TheFlyingKiwi

      How good is having an actual pirate's parrot in your boat building yard!

    72. Tom Oakhill

      There is a reason that bells are made of bronze. Listen to this casting 34:23.

    73. Tom Oakhill

      The meaning of "guys" is "men and women" except in those parts of the English speaking world where "you all" is used. The vast majority of English speakers use it as Leo did here (9:29) . But to those who use "you all" it sets their teeth on edge. There is a wonderful on-line discussion of the loss of the plural second person pronoun in English, and its replacement everywhere English is spoken by "guys," except in a small region (southeastern USA) where it was replaced by "you all." I live in a "guys" is "men and women" region, and first ran into this when speaking to a mixed group where one of the women was from a "you all" region and took offense that I left out her and the other women in the group. I was startled and responded, "but guys means the whole group." She was surprised when all the women present agreed with me.

    74. Tom Oakhill

      The house I live in was built in 1954. They used the newly-available copper-pipes for the water, but used the traditional galvanized-iron fittings at the ends in the two bathrooms, and the kitchen. They had created a battery (7:37), and every one of them was dripping when I bought this house in 1985, at 31 years old. It was not hard to unscrew the iron and replace it with copper. At the end of World War II they stopped building thousands of aluminum aircraft, and began using the (now inexpensive) aluminum in house wiring. But the outlets and switches had copper connectors; again galvanic corrosion set in. Now every home outlet and switch is mandated to come with a label telling you not to do that.

    75. Nick Grace

      Awesome video.....not to mention the best background music tracks of ANY video production I’ve ever seen in my life (33 years). Gotta ask, where’s can I get that playlist!!!

    76. The Chosen

      This dude at 1:50 i had to do a double take i though it was Nick offerman

    77. Ric Furrer

      I like this video very much. 655 can be forged as well which would do well in some cases.

    78. C O

      Boys playing in the sandbox, lol.

    79. chente Pacololo

      Amazing workmanship, u expect couple of trial and errors along the way. But you guys took it in stride . That I think more is a testament to your workmanship overall. FANTASTIC ENJOYED WATCHING

    80. trekchu

      Never knock down laminated wood. They used to make heavier-than-air flying contraptions out of laminated wood.

    81. trevor Gay

      How many did you have to pour...

    82. ninjamonkey2251

      2:38 In your case that's two directions.

    83. Fire Creek Forge

      Interesting all the skills that go into shipwrights work!

    84. Greg Albright

      The amount of money and effort spent on this boat is mind bending. Next time use some cheap ass foam and super glue to make your floor patterns, and saves what has to be thousands of dollars in materials, and hundreds of hours of volunteer effort.

    85. David Lock

      Ya ,ok and everything but your hair is fucked up. Your hair is perfectly fucked up. So we can't believe anything you say.

    86. Fox Vulpes

      Did he say "%94" copper? Jeebus... how much did that cost!?

    87. FMHammyJ

      Now I know why a hand built wooden yacht costs the earth........the amount of hand labour for this process is incredible....

    88. Darksunrise

      It's so weird to see Ron Swanson smile so much XD

    89. Dick Nix

      Fascinating video. Lots of great information of the casting process. I was familiar with the process, but see it actually done on an individual component was great

    90. Chriss Jackson

      If you're going to be anything, be a parrot in a sea of chickens.

    91. nothereforlong

      Oh my God, it's Ron Swanson!!!

    92. j d

      how much did all that casting cost?

    93. Paul Grey

      So this is what ron swanson is up to these days

    94. Mike Gibson

      1:41 woe I thought that was Ron Swanson for a sec

    95. Matthew H

      I love this video. Thanks for putting this online

    96. MoreTimeThanMoney

      I wish I could see this boat in 100 years from now. Using bronze (a highly crystaline metal) against the strength of the sea in a flexible wooden frame... After the explanation of the bronze alloy and seeing them polished... wow!

    97. Kent Klapstein

      I would have so used sodium silicate sand casting on this, wasteful perhaps but way easier..... Yes these guys are pros, I am not but with sodium silicate you can pull of some impressive molds in diy casting. Check out SV seeker, ithomes.info/net/lq6I25inn56Tmpg/video

    98. Jeremy Ogrizovich

      Really cool

    99. SUNGEAR59

      Beautiful

    100. Don Graham

      Wow ! they look incredible even though no one is ever going to see them much ! I would have fabricated steel ones and had them hot dipped galvanised heavy coated . They will easy last 50 years + I bet this bronze molding was expensive even apart from the tremendous cost of the bronze , foundry's are not cheap !