Big Boat Build Workshop

Galleries

Ilen Restoration Hegartys Boatyard Oldcourt Nr Baltimore Co Cork. Photographs © Kevin O'Farrell https://www.facebook.com/pages/Kevin-OFarrell-Photographer/293313657071 Heir Island Skibbereen Co Cork. Tim Lee preparing Oak for the Sampson post bitts. Frank O'Sullivan and Tim Lee supervising workshop participants Joe Walsh, Peter Barry and Scott Barry. Fachtna O'Sullivan fitting new starboard stanchions. Tim Lee cutting Oak for the lodging knees. Tim Lee using the patterns to find the right piece of Oak to make the lodging knees. Tim Lee marking plywood patterns for the Lodging knees. Tim Lee marking plywood patterns for the Lodging knees. Peter Barry AK Ilen workshop participant cutting a tapered rebate for the sheer line blocking. Checking the fit , forward hatch carling. Joe Walsh fitting forward hatch carling. Joe Walsh, AK Ilen workshop participant cutting a tapered rebate for the forward hatch Carling. Frank O'Sullivan and Tim Lee workshop planning meeting. Instructor Tim Lee is from the North West School of Wooden Boat Building Nr Port Townshend Washington USA, who has been invited to work on the AK Ilen Project. http://www.nwboatschool.org/ Finished Starboard side Hanging Knees which will support the main mast deck beams. Paddy Hegarty and Tim Lee working on the Hanging Knees which will support the main deck mast beams. Instructor Tim Lee is from the North West School of Wooden Boat Building Nr Port Townshend Washington USA, Has been invited to work on the AK Ilen Project. http://www.nwboatschool.org/ Tim Lee using a spokeshave to cut a slight concave in the face of the knee to allow the knee to sit better against the frame. Tim Lee marking knee before final cutting. Tim Lee using a Japanese hand saw, cutting the knee to a line scribed by Paddy Hegarty. Instructor Tim Lee is from the North West School of Wooden Boat Building Nr Port Townshend Washington USA, Has been invited to work on the AK Ilen Project. http://www.nwboatschool.org/ Paddy Hegarty scribing the shape of the frame to the knee . Collecting fire wood for the steamer box. The stringers need to be steamed before fitting . Barry Hooper, Ben Hooper workshop participants and Paddy Hegarty, prepairing starboard and Port Stringers. Robin M Pitaluga from the Falkland Islands visiting the AK Ilen, with Lady Cosmo Haskard, Liam Hegarty and Sir Cosmo Haskard, who was the former Falkland Islands Governor-General . Pat Tanner helping with the setup of the Lasser scanning /recording machine, The Lasser scans will be used by Pat to produce Hull line and 3D image/ drawings of the AK Ilen. Lasser reference points, AK Ilen Hull. James Madigan on right discussing the Gandelow a Shannon Estuary Fishing Boat at the new AK Ilen Wooden Boat Building School, Limerick. James Madigan's Currach ( Co Clare) and a Gandelow in the background at the new AK ILen Boat Building Schools workshop, Limerick City. Detail of the original AK Ilen gaff and new mast. The Old AK Ilen frames, in storage at the AK Ilen Wooden Boat Building School Limerick. Nearly three years after its launch, AK Ilen Wooden Boat Building School has moved into a larger workshop in the Limerick Economic Development Partnership (LEDP) complex on the south side of the city. (l-r) Gary MacMahon, director AK Ilen Company, Sue-Ann McManus unveiling the handcarved AK Ilen Wooden Boat Building scrolled name plaque Lord David Puttnam delivering a proclamation at the fitting ceremony 27th May 2011. Ilen's new deck house. A fitting ceremony, arrival of stern deck house. Painting finished stern deck. Preparing aft cockpit deck beam. Notching port side frame for deck beam. Checking notch on port side deck. Double notching for carlins Marking a carlin before cutting. Measuring position of port carlin for stern cockpit. Cutting a notch into the end of a deck beam. Drilling through main poop beam for bronze bolts. Fitting main poop/stern deck beam. Liam Hegarty and Theo Rye Naval Architect checking beam positions. Fitting deck beams Cutting a rebate in the Beam shelf for the deck beam Fitting deck beams. Liam Hegarty and Fachtna O'Sullivan checking deck beam positions on the original drawings for the Ilen. Br. Anthony Keane forester of Glenstal Abbey, discussing with Fachtna O'Sullivan the design points of caulking mallets being made by Br. Anthony for the Ilen. Painting Deck beams, to stop the freshly cut oak from renting (splitting) Cutting deck beam end to shape A helping hand, lifting deck beams into the Ilen. Planing deck beams, checking squareness Cutting deck beams Gary making plans for deck house. Cutting timber for stanchions Fachtna O'Sullivan using a batten and eye to level stanchions Sorting Oak for stanchions Fitting the Breast Hook, used to strengthen the bow of the Ilen, positioned horizontally across the bow. Working on Breast Hook Workshop participants preparing a mould for the Breast Hook Ilen Bronze casting workshops Ilen Bronze casting workshops Ilen Bronze casting workshops Ilen Bronze casting workshops, builders plate Bronze Casting WorkshopsHolger Christian Lónze Bronze Sculptor and workshop Leader. Fachtna and Liam checking the original Ilen drawings with Henry Glass ( Big Boat Build participant ) looking on. The Ilen is now much stronger again as the top of each frame had been fixed between the sheer strake (the top plank) and the beam shelf. Fachtna and Dave drilling a bolt hole through the Port beam shelf scarf. Fachtna O'Sullivan cutting beam shelf scarf. Big Boat Build participants helping Fachtna O'Sullivan clamp together the starboard beam shelf scarf joint Pat Tanner filling the steam pipe with water. Adi Elkabets and Elisenda Caamano cutting a butt joint on the 2nd starboard side plank. Diarmuid Fitzerald cutting the starboard rebate into the stem using an adze. As planking continues each side of the Ilen is measured to ensure each side is identical. Points are located on the plank that are then connected and drawn fair, using a fairing batten. The tacks and batten are removed so the board can be spoiled by cutting away the unnecessary portions, allowing the plank to be gotten out. ( Adi Elkabets checking fairness of line ) Upon completion of scribing at all frames the spiling batten is then laid flat on the board from which the plank is to be gotten out of. The spiling batten is tacked to this board, and then by reversing the process of making distance points on the plank that are then connected and drawn fair, using a fairing batten. Then at each frame a set distance is scribed from the plank to be copied, onto the “Spiling Batten”. This is repeated at all frames. After fairing the frames a spiling batten is bent and twisted into position on the hull, it is tacked to the hull adjacent to the plank you plan to fit a new plank against. Liam Hegarty talking to Janet Jaffray (nee Clifton daughter of the late Capt. Terry Clifton Ilen’s skipper ) Visiting the Ilen and Baltimore West Cork from Port Stanley, Faulkland Islands. Transferring a bevel onto a new oak frame Pat and Fachtna checking the top sheer plank levels on port and starboard before nailing Janet Jaffray (nee Clifton daughter of the late Capt. Terry Clifton Ilen’s skipper ) Visiting the Ilen and Baltimore West Cork from Port Stanley, Faulkland Islands. Countersinking the driven nail Fachtna driving home a bronze nail, Pat holds a heavy object ( sledge hammer head ) against the inside of the frame to stop the nail bouncing and bending. Tools used for refastening. Pat Tanner checking new bronze boat nails ( The Ilen was originally fastened with bronze bolts and boat nails ) Fachtna O'Sullivan guides the forward end of the hot steamed second starboard plank into the stem rebate, ( The steam heats the wood and allows it to bend around tight curves ) The plank has to be fitted quickly before it cools. Fachtna O'Sullivan and Pat Tanner using a batten as an aid to fairing the frames on the starboard side, before fitting a full size plank. Fachtna O'Sullivan fairing the starboard side frames by hand plane. Many hands are needed to lift the hot steamed 38 foot plank from the steam box to the Ilen. Port top sheer plank clamped into position. The first new plank ! Port side top sheer plank steamed and clamped into position. Getting clamps ready on the port side for the top sheer plank ( First new plank to be fitted on the Ilen ) A batten is used to check the Port sheer plank line and fairness of the frames. A water level is used to check if both sides of the Ilen are level before planking commences. Fachtna O'Sullivan cutting the Port rebate into the stem post to accept the first plank end using an adze Diarmuid Fitzerald cutting the Starboard rebate. Adi Elkabets checking the caulking bevel Adi Elkabets using the jack plane to add a caulking bevel to the plank edge. An old wooden Hollow plane. Elisenda Caamano using a small block plane Adi Elkabets using a jack plane and Diarmuid Fitzgerald using a hollow plane Pat Tanner adjusting fence /cut on an electric circular saw in preparation for first cut. Pat Tanner measuring the first plank to be cut. Elisenda Caamano and Pat Tanner Cutting the first new plank for the Ilen Liam Hegarty, Fachtna O'Sullivan, Pat Tanner and Elisenda Caamano Looking for the first plank to be cut . ( Yellow Pine ) Fachtna O'Sullivan cutting stanchions in preparation to re planking. Liam Hegarty fitting frame No 5. Kieran Clancy, a workshop participant, setting up frame No1 Shipwright Liam Hegarty preparing frame No1 on the Ketch Ilen Fitting of frame No. 1 to the ketch Ilen Fionnuala Harvey shaping frame No 24 Diarmuid Fitzgerald workshop participant during Big Boat Build 2009. Framing Out Ceremony May 2010 Br. Anthony Keane – Forester of Glenstal Abbey, Sir Cosmo Haskard – Falkland Islands Governor-General and Dr. Edward Walsh speaking about his role in the repatriation of the good ship Ilen. Framing finished, looking aft towards the stern. Framing finished Looking towards the stern/transom. Framing Finished, looking aft towards the stern. Framing finished, looking forward Frame No 18 - 1 James Mc Laughlin's finished carved Oak Escutcheon on the Ilen stern. James Mc Laughlin wood carver putting finishing touches to the Escutcheon on the stern. Fachtna O'Sullivan Fitting a section of the last frame to the Port side. Fachtna O'Sullivan using a straight edge to check the level of the last frame. Fachtna O'Sullivan preparing the final mould for the last frame on the starboard side. Fachtna O'Sullivan checking transom frame mould/template Fionnuala Harvey double frames are fixed together using bronze bolts Fionnuala Harvey attaching the new frame to original starboard planking ( to hold hull shape during restoration ) Fionnuala Harvey and John Hegarty cutting frame No 21 on the bandsaw. Fionnuala Harvey screw fixing moulds together Fionnuala Harvey setting up plywood moulds/templates for frame No 21 Fionnuala Harvey, Bridin Cannon and John Hegarty cutting out a mould/template for Frame No 21 Fionnuala Harvey and Bridin Cannon ( Mother and Daughter) transferring the shape off the chain mould onto a sheet of ply. Fionnuala Harvey using a chain mould Looking down and forward into the AK Ilen fitting a mould / template No 21 above on the temporary deck beams used moulds are stored. Bridin Cannon reapplying paint to stop the oak frames drying out. Looking forward into the AK Ilen temporary braces hold frames and hull shape together Big Boat participant removing copper sheathing from hull Peter Collins and Charles Hurley preparing Frame No 27. Transom planks are caulked with a mastic before assembly AK Ilen Restoration Hegartys Yard Oldcourt West Cork All Photographs copyright Kevin O'Farrell 2010 Heir Island Skibbereen Co Cork Ireland Pat Tanner and Fachtna O'Sullivan fitting the bottom transom plank Pat Tanner and Fachtna O'Sullivan checking the level of the first plank Pat Tanner checking bevel on first transom plank Transferring the transom bevel onto the first plank end From the transom, bevels are taken off and then recorded onto a bevel board Workshop participants transferring centre line from mould / template onto Teak transom plank Transom mould joined being taken down from the lofting area Fachtna O'Sullivan shaping the starboard transom mould. ( due to size two moulds were made, port and starboard, and joined later). Measuring stern post Workshop participants checking stern post Brother Anthony, Forester of Glenstal Abbey, giving a talk to workshop participants on wood Mary Johnny Joe O'Driscoll priming installed frames Pat Tanner mixing linseed oil with putty for bedding stern components Transferring mould measurements to frame Fachtna O'Sullivan checking frame width Donal Lynch drilling through frames for the bronze bolts John Hegarty frame No 16 Port side Traditional shipwright Fachtna O’Sullivan fitting frame No18 Críostóir Mac Cárthaigh cutting in a bevel with spokeshave Críostóir Mac Cárthaigh checking bevel angle on oak frame No 19 Hand made Bevel gauges awaiting use Dermod O’Brien and Fachtna O’Sullivan preparing an oak floor, AK Ilen restoration Fachtna O’Sullivan and Dermod O’Brien (grand nephew of Capt. Conor O’Brien, first skipper of the Ilen) preparing an oak floor Shipwright Toby Graystone checking level on a oak frame Fitting the A K Ilen stern post Fitting a stern knee Diarmuid Fitzgerald workshop participant during Big Boat Build 2009. Cutting stern post tenon AK Ilen Restoration, in the back ground is a John Hegarty punt with frame moulds and battens in place, ready for framing. Preparing stern timber for the A K Ilen restoration. Installing a stern post knee in the A K Ilen, Big Boat Build 2009. Big Boat Build participants fitting the stern post knee. Fachtna O'Sullivan, John Hegarty and Pat Tanner cutting an Oak knee. Tea Break ! the yard cat looks hopeful ! Gary Mac Mahon working on the stem of the AK Ilen Liam Hegarty giving advice to Kieran Clancy Original Ilen keelson reinstalled, view looking towards the bow. Working on the Keelson Workshop participant cutting a rebate in the forward end of the keelson. Liam Hegarty preparing to fit a new Oak floor in the Ilen. Fachtna O'Sullivan creating a frame mould / template. Fachtna O'Sullivan preparing rebate for Oak Floor. Fachtna O'Sullivan cutting joint for the Keelson ( forward end ) Many hands working together to re attach planking to stem. Fachtna O'Sullivan, cutting a frame with the late Capt. Terry Clifton looking on ( Ilen's skipper, Port Stanley, Faulkland Islands ). Fachtna O'Sullivan using the bevel gauge to set the angle of cut on the band saw. Pat Tanner and Fachtna O'Sullivan preparing a frame for cutting on the band saw. John Hegarty cutting an oak frame with a chain saw. Fachtna O'Sullivan and John Hegarty making a pattern from an old Oak frame. Fachtna O'Sullivan The mould is laid onto a plank of Oak for its shape to be transferred, before being cut roughly with chainsaw. Liam Hegarty, Fachtna O'Sullivan and Donal Lynch selecting Oak for frames. Fachtna O'Sullivan and workshop participants using the mould/template to mark /outline the frame. Modern (Chainsaw ) and Old (adze) boat building tools in foreground. Dermod O'Brien ( grand nephew of Capt. Conor O'Brien, the first skipper of the Ilen) preparing an Oak plank for frame No 18. John Hegarty using an Adze a traditional boat wood working tool. Paddy Hegarty and Fachtna O'Sullivan check an Oak plank for any defects on the underside before cutting. Oak Timber for the AK ILen Grown Oak Timber arrives for frames. Liam Hegarty removing bronze fastenings to frame No 10 Traditional shipwright Fachtna O'Sullivan cutting bronze bolts holding the grown oak frames together. Mary Johnny Joe O'Driscoll cleaning frames prior to removal, looking forward towards the bow. John Hegarty Building a 'Hegarty Punt' underneath the shadow of the AK Ilen AK Ilen Hegarty's Boatyard Gene O'Neill and Fachtna O'Sullivan supervise the AK Ilen into her new home, an old grain store on the banks of the River Ilen. Liam Hegarty directing the arrival of the AK Ilen to the Restoration Shed. AK Ilen takes a short trip on the River Ilen to restoration shed. ( this was the only way of moving the AK Ilen from one end of the yard to the other ). AK Ilen being loaded onto Barge.

Photo Gallery

Ilen Restoration Hegartys Boatyard Oldcourt Nr Baltimore Co Cork.

Photographs © Kevin O’Farrell
https://www.facebook.com/pages/Kevin-OFarrell-Photographer/293313657071

Heir Island
Skibbereen
Co Cork.

 

Educational Programme

About Our Charity

The Sailing Ship Ilen

 Supported by
This project is supported by the West Cork Development Partnership under the Rural Development Programme 2007-2013