The Bow Sprit ~ Part 1 ~ Construction

The original bowsprit was easier replaced than repaired. There was extensive, structural corrosion. The new 'sprit builds on lessons learned, with stainless inserts at the wear points and stainless steel anchor roller brackets, as well as a bolt on design closer to the original blueprint specifications.

The 6" by 1/8" square steel tube was impossible to obtain, so I had a machine shop bend 11 gauge sheet into channel so I could weld it together to form a square tube. I also considered using schedule 10 or 5 pipe in 6", but found that that was unobtainium as well, with the Chinese evidently absorbing the entire global supply of petroleum pipeline pipe. Hmmm.

Here, Blayde helps with the spot welding process to hold the parts in place for final welding.

Welding the channel sections together to form the main tube.

The 5/8 plate bullnose, after final welding. This will bear the majority of the loads on the bowsprit.


Bullnose in place, awaiting stainless inserts in the holes.


Reaming the stainless inserts. Here you can see the bullnose, as well as the stainless axle tube and rub plates.

The inner forestay mounting eye, with ears below mounting it to the cutwater. This is a continuous piece of 5/8 plate that bears the loads from the inner forestay directly below to the massive steel cutwater on Free Spirit.

Grinding, showing the stainless anchor roller ears. The stainless axles that the rollers turn on go through stainless steel tubes welded through the 'sprit. The rollers rub on stainless rub plates to prevent paint wear. These details should prevent the damage that caused the early demise of the original bowsprit.

Fashioning the aft end of the bowsprit. Here a stainless eye will attach the after part of the new spar to the deck.

Here, Finished.

View from above.The boys did all of the grinding on the new spar! The entire surface had to be ground to remove the mill scale, which would prevent the paint from adhering as well as it could.

Valin, hard at work. One day, we found him grinding away before anyone else was even awake!

Blayde, focused on the task at hand. Although not pictured, Drake used the air powered die grinder to grind all the stainless parts, his contribution to the grinding effort.

Shiny!

After grinding showing the construction details. Note the stainless inserts welded into all of the attachment points.

More of the details, after the surface prep. The inner staysail attaches to the eye behind the inner forestay. this eye is designed to allow easy caribeaner access for anyone working out on the 'sprit in heavy weather.

Oliver from P'tit Lois helping to foam the new spar with 2 part foam.

Pouring the tricky stuff in.....

....And waiting for it to expand.... what a mess!

The foam will help to keep the bowsprit corrosion free.

More on the bowsprit soon!!!!