The Beginning of the (fore)End

[CaptJake]

Well..........................It's that time of year in Oklahoma where it's still not too cold to sail but we seem to get bored and start looking for something on the boat to tinker with.
And so...................in that spirit I have decided to put the bowsprit back on the Najade. She started out life as a cutter and I have recently come across a design that I think will work quite nicely. I'll start with just a few photos of the start of this project and I'll keep ya posted as I go.

 

[CaptJake]

Here's a pic of the original pulpit after it was removed. The removal process was pretty straight-forward.................break two wrenches, drop one overboard, cuss, hit bolt with hammer, cuss some more, break out sawzall..................no sweat.
Actually it wasn't that bad really, the PO and myself are definite converts to the anti-sieze, butyl bed tape, church and I had the thing off in less than 30 minutes.
Got it into my shop and affixed it to a homemade jig (to maintain distance and spacing) before the cutting began.

The idea behind the design is rather ingenious.............the sprit itself joins into the pulpit at the base and carries forward and will also be used to support the new life rails which will also be added to the pulpit. Instead of traditional "whisker" and "bob" stays there will be a lower spreader frame which will keep the sprit from twisting and will act as the anchor point which attaches low on the hull..............more on that later.

 

[CaptJake]

And here is the second in the series after I got the outboard body frame of the sprit cut, bent, and formed. It hasn't been attached yet as I'm going to have my brother TIG weld it because I don't TIG weld. FWIW................stainless steel heavy wall is a bear to work with and will take up alot of time. Happy with the way it's turning out so far, but, as this is going to be a weekend project (I work alot), it might be a slow-moving thread. That's all I got done this weekend......................more to follow.

 

[Merlin Clark]

Lookin good!

 

[Mikem]

Chief, nice work.

 

[CaptJake]

Thank ya gentlemen..................
Been kinda slow at work so I've been able to get ahead of my own schedule. Was just getting ready to post a few more progress reports. Still looking for a few more parts for the rebuild/upgrade but moving right along.

BTW Merlin.................found a rigid boom vang dance down in your neck of the woods (dirt cheap no less), should get it today or tomorrow.

 

[Merlin Clark]

Thank ya gentlemen..................
Been kinda slow at work so I've been able to get ahead of my own schedule. Was just getting ready to post a few more progress reports. Still looking for a few more parts for the rebuild/upgrade but moving right along.

BTW Merlin.................found a rigid boom vang dance down in your neck of the woods (dirt cheap no less), should get it today or tomorrow.

Need help?

 

[CaptJake]

Got the actual bowsprit section bent and cut to length after work on Monday. Still not welding anything up as my Brother had to order a new hand control for his TIG and I really wanna get the "hoops" built and mocked up to check fit and get the birdsmouths ground. This will be the first extension attached to the bottom of the existing pulpit and will extend the bottom out approximately five feet.

 

[CaptJake]

I will NEVER turn down help friend, (no good sailor ever should) so drive your butt up here and get to welding! As always........................I shall have beer and rum available.

 

[Merlin Clark]

I will NEVER turn down help friend, (no good sailor ever should) so drive your butt up here and get to welding! As always........................I shall have beer and rum available.

There we go Jake! Last welding I did was rebuilding the intake boxes for the Port Everglades power plant.
Almost got a snook with my 2 lb hammer.....

WHAT WAS I THINKING!!! Free beer? I'll be right there!

 

[CaptJake]

This is the initial mock-up of the sprit and the lower life rail (yes, it is held together with electrical tape for now.......................MaineSail will have me swingin' from a yardarm for that but it seems to work). The end hoop extends 10 inches past the end of the bowsprit and the top rail and hoop will extend ten inches beyond the lower in order to maintain the original "lines" of the pulpit.

 

[CaptJake]

I WILL NOT comment on how wrong that is. Fishing within xxx feet of a dam or power station is unlawful sir......................and they're too fast to hit with a 2 lb hammer. Use a slag hammer, cuts water faster (eg. faster head speed), and it's pointy.

FWIW.................I think we just resurrected the wine bottle, life raft, kill sharks, thread.

 

[CaptJake]

Front and side views of the first mock-up.

 

[CaptJake]

Wednesday (yesterday) I got the top life rail extensions cut and the end hoop bent. Seems to be coming together nicely. I will need to get the birdsmouths ground in now and the pieces welded together (tacked actually) so I can start on final spacing and the support system. The sprit itself will have an integral anchor roller and cross tube supports and the life rails will have support elevators per the original "look" of the pulpit. Haven't cut out the original top hoop yet as I need it to maintain strength and spacing for now. It will be removed later in favour of the new "extended" version.
Kinda in a holding pattern for a little bit now 'til I can get this moved over to my Brother's house for welding.

 

[Merlin Clark]

I WILL NOT comment on how wrong that is. Fishing within xxx feet of a dam or power station is unlawful sir......................and they're too fast to hit with a 2 lb hammer. Use a slag hammer, cuts water faster (eg. faster head speed), and it's pointy.

FWIW.................I think we just resurrected the wine bottle, life raft, kill sharks, thread.

I had it pinned with my light, and it was DARK in the box. Didn't think about the slag hammer....

 

[Merlin Clark]

Can't wait to see it on the boat.

 

[CaptJake]

Well Campers..............
After two days of grinding and welding (wow, TIG is slooooow), we have most of the sprit and pulpit frame welded and/or tacked in place. Matt (my Brother) will get the rest of the welds finished this week and then its off to the boat for a test fit and adjustment before we start on the support structure in earnest.

 

[MrBee]

Looking good,

 

[rpwillia]

Bending

What are you using to bend the rails with? In one picture near the top of this thread it looks like you have a simple hydraulic pipe bender.

 

[CaptJake]

Yep................hydraulic pipe bender. Used pretty basic tools to do this.