The ballast keel box is completed! I finish with the lead melting and pouring and the box is filled to the brim (nearly). Some mounting points are attached to fit the sacrificial zinc anodes and finally, I seal the top of the box with a nice smooth pour of epoxy.

This is the story of the building of a Jay Benford designed, 31.8ft, junk schooner-rigged cruising sailboat. The videos are a week-by-week record of the build as it progresses and aim to show as much detail as possible of the various aspects of the build.

These videos take a lot of time and effort to make, in what is already a time-intensive project. Your support in watching, subscribing and sharing these videos is very much appreciated. You make a real difference!!

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Music tracks "Sit and Wonder", "Ocean View" and "The Great Divide" available on iTunes, Amazon etc. EP "Shake a Leg", album "Out of the Moloch", single "Ocean View".

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Music from these videos is available from: https://ynotb.bandcamp.com/album/the-sv-tapatya-tracks

Thank you :-)

Tony

Closed Captions (CC):

0:03
[Music]
0:08
hi i'm tony and this is the story of the
0:12
build of this 31 foot eight inch jay
0:14
benford designed cruising sailboat
0:17
from the lofting of the lines to her
0:20
emerging from the boat sheds to receiver
0:22
keel masterson all the other
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paraphernalia that make up a cruising
0:26
vessel
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join us on this adventure as we
0:30
build topacha and hopefully set off to
0:33
test her out as a liverboard cruising
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vessel
0:37
[Music]
0:59
so
1:18
hi i'm tony this is let's feed to badger
1:22
and yeah here we are sat next to the
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keel last week i'd started filling up
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the kill with lead the forward end was
1:30
was progressing was almost full but the
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after end i hadn't started filling that
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because i needed to get these two
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metal pieces on the aft end these
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provide some locations some wood that
1:43
comes along the back here and these
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provide some location for that
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so i had to get them on and i was had
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been waiting for the metal to arrive
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um it arrived i think the day of
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the day i was editing the the video last
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week
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then yeah first job was to cut those get
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them on
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and then to get on
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melting lead
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and filling the kill box
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6:06
uh
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okay
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so
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oh
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so
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oh
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good
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so
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foreign
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so
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foreign
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so
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so
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so
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there's me somewhere in there
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i've got two of these nice big zincs
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that are going to go
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each side
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and i needed to make some fixings for
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them
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um and so i've welded just a couple of
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nuts on there for now
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um i may well use another nut on top of
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that and just have studs sticking out
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to actually fix them but this the first
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nuts on there
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for the fixing for those things i say
15:38
two nice big things
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one each side
15:42
for protection
15:44
and that's come out well
15:46
yeah once she was nice and full
15:49
the final job was to pour some epoxy
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over the top fill it up flush to the top
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it was only a couple of millimeters
15:58
below the top but it wasn't quite flat
16:00
fill it up flush and just also seals it
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because
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the lead doesn't stick to the steel as
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you probably know
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um and as the leg cools it pulls away a
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bit from the steel so you get a little
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gap between the steel and the lid
16:16
obviously one of the big advantages of
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doing multiple pores is that
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when you you know the lid pulls away a
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bit the next paw goes on and runs down
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in that gap so it's successively filling
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that gap so the gap in the end is very
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very small
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um but i wanted to and i have now
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poured a nice lot of epoxy over the top
16:37
that gap is now non-existent i went
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around with a grinder and ground the
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inside that little lip around the inside
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so it was clean to get a good bond
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between the epoxy and the steel
16:49
and that has sealed things perfectly now
16:51
and i'm very pleased with it nice flat
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surface i say that is this sealed to the
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steel
16:57
uh come out very well
16:59
now a couple of people asked me how many
17:02
pores were involved and i shall give you
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a few numbers now
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um
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the
17:08
design weight for this keel is 1280
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kilograms
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um obviously
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it's in pounds but i've converted it all
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1280 kilograms design weight now i
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wanted to be a bit over that
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um
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up to
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but possibly up to 10 percent over that
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was my goal but attempt perhaps a
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fraction a bit under 10 was my goal
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so um i've i had 1300 kilos of lead
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the steel box weighed in 100 kilos
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um which would have given me a total of
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1400 but i've got a little bit of lead
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left over about 50 kilos of lead left
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over so i've melted 1250
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kilos of lead
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100 kilos for the box 1350 brings me
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nicely a bit over five percent
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overweight i'm very very pleased with
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that perfect i think
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um
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so i melted 250 kilograms of lead
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and i've measured my average lead poor
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quantity
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to be five and a half liters
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um so i'm doing five and a half liters
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per port
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let's uh eleven point three four
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kilograms a liter
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so do the math you'll work out that it's
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110 liters in total of lead
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at five and a half liters of poor 20
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pours and i reckon that's where i didn't
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count but i think that's about right 20
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pours
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and
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i say come out very well another
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important thing to say i think is that
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that when i'm pouring
18:45
in there
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if you've watched leo or taliho the
18:50
first time he attempted to pour his leg
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keel
18:53
you'll notice that as the lead run in it
18:55
melted the existing lid and caused the
18:58
issue it sort of dug through under the
19:00
formwork he put there
19:02
it melted and
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that's what i want to say is i could see
19:05
this doing the same thing not not going
19:08
under the formwork but i could see as i
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poured the fresh molten laid in i could
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see it melting the layer below so i'm
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confident that it's got a really good
19:17
bond there at least a you know a decent
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bond
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there's no doubt that it was melting
19:23
that lower layer as it went in
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so very pleased with that
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coming up myself now finished epoxy in
19:31
it
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the next job will be to get it up in the
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air sandblast it
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i've got a little blaster which i've
19:37
never used to see how that goes
19:40
sandblaster if not i'll grind it
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and uh
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seal it with a zinc rich epoxy primer
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which arrived yesterday so
19:49
ready to go there
19:51
and i've i have actually moved this a
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little bit i jacked it up with my normal
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car jack that i use for the boat
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moved easily
19:58
jacked up easily at least and of course
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it'd be easy enough to jack it up get
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some rollers underneath it to roll it
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to and fro at least
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so we're coming on well we've got the
20:09
ballast kill made sat over there you can
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see the wooden
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fuel timber
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at least most of it all all the wood
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kill timber that goes above this is
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there there's a little bit to come that
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runs off of this ballast kill box
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to the aft end of the boat that provides
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the support for the rather the lower
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rudder shoe
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that's still to make and i'm sat on the
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wood that is intended to be that
20:36
so i'm making great progress and i'm
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very very pleased to have this done
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tiredly and it's come out well
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[Applause]
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[Music]
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[Applause]
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[Applause]
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and that guys is it for this week
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massive thank you to you for watching
23:06
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23:08
project on patreon and paypal
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give us thumbs up hit that subscribe
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we'll be back next time see you then
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my
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[Music]
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is
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[Music]
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you