Center for Woodenboats casting class

In contrast to the modern day materials including carbon fiber and delrin and the magical bonding elixirs like two-part epoxy, it's nice to get our hands the ancient arts and methods including wood nails, frame lashing and perhaps the most awesome, bronze casting.  

A small crowd gathers on a winter's day around the glow of the furnace

On several occasions James McMullen has set up to cast special nameplates for the boats we have built, custom hardware, oar locks, pintles, etc.  The Marine Skills Center has been hosted for one such demonstration, and James has most recently rounded up many of his Sail and Oar posse for casting sessions with particular attention given to those who need pieces that are hard to find in the retail setting, such as gudgeons for a double-ender.

On the weekend of March 22 and 23, James will be teaching a casting class at The Center For Woodenboat-Cama Beach.  This class is sold out, refer to the link provided below for information on future classes.

James McMullen Bronze Casting at Cama Beach

Your basic small foundry furnace set-up

Wooden "flasks", ready for pouring.  

A pattern for a sounding lead, being made up into a flask.

For more pictures, videos and lively commentary!

skimming off the dross. . .

The graphite crucible in the center glowing with molten bronze

That crucible is actually dark gray-black at room temperature.
Not currently at room temperature.

Breaking the part loose from the sand.

The metal is still so hot that the sand bursts into flames again when exposed to fresh oxygen

The used flasks--the charred parts are where the molten metal contacted the sand.

Windsong's New Rudder and Tiller

On a drizzly day in November 2012, Windsong was hauled out for a few phases of work which would result in a mid to late summer 2013 re-launch.  The spars were removed and lain aside for inspection and eventual touch-up varnishing in the warmer months. 

Andy had ideas for a new rudder design which would perform better and the haul-out provide an opportunity to inspect a few other things he was concerned about below the waterline.  He was looking for more responsive steering, more predictability backing (if possible), better flow around the propellor aperture and way to remove the rudder with out having to lift the boat. As the boat is over 50 years old, it became apparent that building a new rudder was the best way forward.

Naturally, as things progressed, it became evident that with a new rudder, also should come new gudgeons, pintles and tiller. So it goes.

Bending the bronze rudder post

Preparing to cast the bearings for gudgeon and pintles.

The old rudder head 

Rudder head salvaged from Lyle Hess's Boat

Freshly polished 

Old and new parts and pieces.

Plane and chisel make one side of the notch that fits in the groove fitting rudder together

Bronze rods tie the oak pieces together

rudder post and strapping

New Gudgeon

Bedding compound where the bronze rudder post straps set

Hung and balanced

Andy clamps the glued tiller to the mold

James carves the scroll on the tiller head

Fresh paint and ready for launch

The beautiful mahogany tiller makes the picture is complete.

So while the summer of 2013 was full of spectacular warm weather and windy evenings, boating thrills were delayed.  But with paintwork all ship-shape, new rudder, steering system and tiller in working order, Windsong provided her crew with some late summer, fall, and winter outings.