5.09.2009

Sampson Post Repair - Westsail 32





I was poking around the Sampson Posts on Mary Rose V the other day and decided it was time to restore the finish on them. It looked like the previous owner had done a very good job protecting them with multiple layers of Captain's Varnish. Cutting the tops of them off of the Sampson Posts and placing caps on the end grain had also been on my project list for some time now and this seemed like a good time to take care of this item on the project list. I had just found a beautiful piece of Bloodwood that would make a very nice contrasting color for the end grain caps on the Sampson Posts. I plan on using the remaining Bloodwood for blocking at the base of the mast compression post. While I was poking around I noticed a small plug of epoxy inboard, near the bottom of the port Sampson Post. As I poked it became loose and I was able to pull it out and was startled when my screw driver went completely through the post. YES, IT WAS TIME TO REPLACE THE ENTIRE PORT SAMPSON POST! When we bought Mary Rose we received one hull and enough spare parts to build three boats. Thank you Larry!!!!!!!!!!!! As luck would have it, the spare parts included a Sampson Post!!!!!!!!!!! All I had to do was drill the holes in the correct spot and install it. I pulled the rode and chain from both lockers and began the process of

removing all of the fasteners so that the post could be extracted. I used my Fienmaster Multi Tool to trim and square up the hole through the deck. The rot in the Sampson Post seems to have also allowed a small amount of the plywood in the foredeck to rot as well. I mixed and thickened some West System Epoxy and injected it into the space through the hole for the Sampson Post with a 60 ML catheter tip syringe. I then used a heat gun to get the epoxy to rapid set so I could install the post. I drilled the new Sampson Post and then gave it a test fit. This is where I found out that I had missed one of the marks for the main hole that attaches both posts to the Stainless Steel Bow Sprit. I simply filled the hole with epoxy and re drilled it after the epoxy set up and it worked fine. I bolted the new post in place and then sealed up the hole in the deck with some two part epoxy putty. The next day I used Teak Decking System SIS 440 to reseal the teak decking to the Sampson post. The final step in the process was a complete finish application of The HONEY TEAK System from Signature Finish. The Honey Teak System is a two step, catalyzed acrylic urethane enamel coating that really delivers on performance in tropical climates. You can read more about Honey Teak at http://www.signaturefinish.com/index.php?topic=Home We are in the process of removing all of the other old finishes and replacing them with Honey Teak. The Sampson Posts were the first items complete. I did give the Sampson Posts a couple of coats before sealing the deck so there would be overlapping protection. The Sampson Post replacement was NOT on our list but it was not a big challenge. Much less difficult than I would have imagined.

Stern Arch - Boom Gallows - Westsail 32






The boom gallows, stern arch on Mary Rose was original. It served Mary well for several decades. We felt we needed to replace it so we could create a design that would support new and necessary technological advances in navigation and energy generation. Yes we could very well have pieced together all of the individual items with their own various mountings, brackets and pipes. However we choose to redesign the entire aft stern arch. This allowed us to take advantage of several options that would not be available to us if we had just added on to the original arch. The advantages include, all wiring enclosed within the tubular framework, a hard rail design that allowed for cockpit seating, opening up additional deck space on the aft end of the boat, articulating arms for solar panels and more. We were fortunate to find it a new home on the Sailing Vessel Shaboom for the original boom gallows/arch that was removed. This has become a very nice trend, almost all of the items that have been removed from Mary Rose have found their way to new vessel for an extended life with new owners.

We contracted with Suncoast Specialties, 9161 131st Pl Ste F, Largo, FL 33773,727-584-3252 for this project. Bill (owner) worked closely with us from concept to final welding. The design was a joint effort between Suncoast, Admiral Nelson and myself. Bill took the original measurements and created the base design. We then worked off of some rather crude scale drawings that I did to assist with placement of the items to be hung on the arch. Bill tacked the base design together and delivered it for a test fit on the hull. We made a few modifications and we brought it back again for another test fit. The second test fit proved to be a very good idea. It was still tacked together so we were able to move the angle of the feet on the base so that they fit perfectly on installation.
We welded two inch stubs on the end of each leg so that the base would extend completely through the cap rail on final installation. The stubs were bedded with 3M 5200 and the bases were through bolted with 3/8 SS 316 bolts and fender washers. We were able to reach the back legs for through bolting by removing the hawse pipe flanges. These needed to be re-embedded anyway, so it was no real issue. The front legs were easily accessed through a removable port that was installed by a previous owner to bolt on the wench mounting brackets.
We pulled all of the wiring through the front legs as there is additional welding required on the back legs to accommodate the cockpit rail seating. The front legs have horizontal stubs welded on them to accept the 1 inch tubing for the hard rails going forward. The only wire for lifelines will be at the gates located at the shrouds on both sides of Mary Rose. We feel that the 1 inch hard railing enclosure will add a tremendous amount of safety to staying on board in rough seas with only two crew members aboard.
This was a very large project relative to the work that remained to accomplish prior to departure for our long awaited journey. This was a tough one as it caused us to remain tied to the dock during the process. No Sailing = No Fun!!!!!!!!!!!!! The Admiral and I can hardly wait for another extended sea trial to test all of the systems that were just modified.
Here is a detailed list of the items that are attached, supported by or will be attached to the stern arch when it is complete.

Garmin 18” HD Radome
GPS Antennae
Stern Nav Light
Aft Looking Flood Light
Forward Looking Flood Light
Loud Hailer (auto fog horn!!!!!!!!, we love this feature)
#2 VHF Radio Antennae
One 60 Watt and Two 110 Watt Solar Panels
Ships Bell
Satellite Antennae
Alpenglow Red/White Cockpit light
#2 VHF RAM Mic
Headsail Cleats
Cockpit Seating (3)
Boom Gallows
Pad Eyes For Tiller Ties
Bimini Framework

We will post more photos as we bring this project to completion.