Taking Things Apart

The building is erected, the lumber has been retrieved, and the real work begins.

Essential Preparations

When we last left off, a temporary building was being erected over the Firefly. While this sounds like a big undertaking, it is more similar to the temporary covers most boats put up when they are out of service for a few months. Plastic is stretched over a frame, taped into place, and then shrunk with a heat gun. Though simple, it provides crucial shelter from the wind and snow, and a wood stove installed in one corner takes the edge off the chill.

With the Firefly safely tucked away for the winter, the next step was to acquire lumber for the rebuild. Family connections took Becky and Nathan to a sawmill in Tennessee in mid-January. They returned with a box truck stacked full of still-green oak, which will be ideal for steam bending into new frames and planks for the Firefly. The higher moisture content in green wood makes it much more flexible, and paradoxically the wood will dry much faster once it is steamed.

Work on the Boat

Before any real repairs could begin, the underlying condition of the Firefly had to be assessed. It was obvious that the covering boards were rotten, and that the once-galvanized hardware was rusty, but how was the hull planking? The frames? Over the course of the last few weeks, Nathan has stripped decades worth of paint from the Firefly’s hull using a Paintshaver, while Ken began pulling the ceiling planks from the interior. The bulkheads were removed for ease of access, leaving temporary cross bracing to help the Firefly retain her shape. The exterior transom planking was removed as well.

Above: The ceiling planking removed from the forepeak, revealing the frames beneath.

Above: A view of the entire interior of the Firefly, as seen through the now-exposed transom

Above: The transom, sans planking.

The condition of the Firefly’s structural elements is uninspiring but not unexpected. Many of the frames will need to be at least partially replaced, along with parts of the transom. One such frame was so soft it could be easily knocked out with a chisel, leaving a line of fasteners behind.

The fasteners we uncovered included both her original iron cinch nails and stainless steel screws from maintenance done in the intervening years. In some ways, a rebuild can feel like an archaeology project.

Above: Removing a rotten frame.

Work on the spars and rigging

The Firefly’s rebuild isn’t just limited to the parts of her that float; the spars and rigging are also being carefully assessed and repaired.

The old sails have been sent to Gambell and Hunter Sailmakers, a local sail loft that has made sails for this vessel for decades. A new set has been ordered, with a few modifications (stay tuned).

Meanwhile, Alex has been stripping paint from the spars with a heat gun and a scraper.

So far, every spar needs work, from minor dutchmans to scarfing in entirely new sections. Much of the hardware is worn and will be replaced.

There have been some interesting surprises, including a star sketched in pencil on the tip of the bowsprit that somehow survived decades of paint and wear.

The heel of the bowsprit, on the other hand has significant damage and will need to be completely replaced. Using a chainsaw, the damaged section was removed and a further section was cut at an angle to prepare it for a scarf.

Repairs Begin

In the next few weeks, we will build a  steam box at the shipyard and shape oak for new frames. Meanwhile, in the shop, we will begin to laminate and shape fir planks to form a new heel for the bowsprit.

The Firefly will also begin hosting occasional open houses at the rebuild site at North End Shipyard in Rockland. The first one is today, February 6, from 5-6 pm. If you happen to be around, feel free to stop in and see the rebuild for yourself!