What’s New in the Shop: 2009-2010

June 14, 2010: BRENDA KAY is launched


Winter 2009/2010

43ft power cruising boat DELIVERANCE
29ft cold-molded lobster boat BRENDA KAY
14ft glued lapstrake tender BERNADETTE for electric power
28ft cat-yawl MOLLY B restoration


Designed by Doug Hylan for a long-time customer, construction of this 43′ powerboat continues. See Spring/Summer 2009 for earlier photos.



With the planking complete, the deck beams are fitted and installed.






The horseshoe stern after installation of the deck beams.







Work begins on the interior. The forward cabin is shown here.







The sheer plank is wider than most of the other planks, and we steamed it beforehand for easier installation.

MOVIE DOWNLOAD AVAILABLE: Click the image at left to see a “movie” of the steaming of this plank. The movie shows the plank being hustled from the steambox (located just outside the shop door) and clamped into place. It is a 13MB AVI file.


As planks are added, the complex shape of the horseshoe stern begins to emerge.







The temporary ribbands are removed as planks are spiled, shaped, and fastened to the boat.



This new boat is based on DIANA, a 1950s Beals Island lobster boat that we rebuilt in 2002 as a picnic-style boat. BRENDA KAY is cold-molded with an inner layer of white cedar strips reinforced by two layers of red cedar veneers.



With the boat now right-side up, the keel is attached and work on the cockpit, superstructure, and interior begins.






Turning the hull.







The first layer of red cedar veneers is epoxied to the strip planking. On the right side of this photo is the laminated keel. It will be installed after the hull is flipped over.




The first few strips of white cedar are epoxied in place. Once the strip-planking is complete and the hull is faired, two red cedar veneers will be vacuum-bagged to the strips to make a strong watertight structure.



The main bulkhead (made of mahogany plywood) is faired into the setup as well. The bilge stringers provide excellent support for the engine beds to come later.




Here we see the complete setup being faired for planking. The hull is built upside-down, and the keel, stem, bilge stringers, and sheer clamps (all made of Douglas fir) are notched into the molds. The mahogany plywood transom is set at the correct angle and cross-braced to prevent movement during planking.




One of the first steps in building BRENDA KAY is to laminate the inner stem on the loft floor.


14′ Glued Lapstrake Tender BERNADETTE

This tender, a new Doug Hylan design, incorporates built-in batteries for quiet and efficient electric propulsion. Glued lapstrake construction ensures a lightweight hull while varnished teak sheerstrakes and seats accent the classic lines.



The MOLLY B is a 27’9″ cat-yawl designed by C. C. Hanley in 1927. She is in our shop for new frames, floors, some new planking, refastening, and other major structural work. She is in quite original condition–most of the restoration work is the first since new–and the restoration will use original techniques as much as possible.


The interior, ceiling, and centerboard trunk were removed to get access to the frames and floors. This photo shows the new frames and most of the new floors in place. It also hints at the roominess of the interior. In typical catboat fashion, she is quite beamy at 11’9″ on a 24′ waterline.



The cockpit and lower part of the main bulkhead were also removed for the project.







The old fasteners were removed and the old screw holes reused whenever possible.