CLOVER Restoration Project - Haul-out and Deck
Restoring a Dunkirk Veteran Boat to Serve Veterans
First, the haul-out phase is scheduled to being in June, will cost $25K and will consist of the following:
2. Hydro wash and Prep Bottom for painting (we’ll have the bottom paint donated and volunteers will paint the bottom)
3. Prep and paint the topsides two coats epoxy (same as before in 2016)
4. Replace zincs
5. Replace cutlass bearing
6. Remove aft cabin (it is prepared for removal and has been disconnected from the deck so is ready for lifting)
7. Remove the main cabin (this is an option we may exercise - in preparation for replacing the deck, and it would similarly be prepared for removal).
8. Prep and Paint the bilge in the engine room, and reinstall the engine.
the boat back in the water we will embark on replacing the deck and supporting
structure, is the largest and toughest on this project, and estimated to cost $45K in skilled woodworking labor and materials and take 10 weeks.
This phase starts with removing aft cabin from the boat, quite possibly the main cabin (once we’ve opened up the deck to find out the condition of the supporting carlines and jackbeams), and the hatches as well. I've made a start with Jeff Rutherford of Rutherford Boat Shop and together we disconnected the aft cabin from the boat so it is ready to be lifted off by crane. Once removed they can be stored and the work can begin on with veterans restoring the cabins; the hatches have already been restored and can be quickly removed.
Once all these structures have been removed from the boat, we can move on to removing the deck. This will involve pulling up the fiberglass covering that we put on to prevent rainwater from leaking into the boat, and to protect the joinery between hull and deck. That’s a dirty job but I want to save the teak underneath and not just take a saw to it. We have some beautiful long pieces of teak decking that is ¾” thick that can be planed down, holes plugged, and re-used to go atop the new deck. This is painstaking work but doable with volunteers. We will remove the teak decking carefully, recording on each piece where it came from, and transport to Rutherford’s for planning, plugging the screw holes, and storing it until needed. With the teak is removed then we can remove the deck beams underneath, many of which need replacing. We will laminate replacements using the original beams as templates. Starting from forward aft, we will replace the beams one by one to put strength back into the boat and also to preserve her shape - otherwise she will open up along her width. We will also replace jack beams and carlines where needed underneath the cabins. All beams will be of red oak preferably or live oak ideally if we can afford it. The boat deserves it.
With that done the plan is to lay a new deck on her, using as a sublayer Okoume marine plywood; two sheets of 1/2" thickness to ensure the plywood can take the proper shape of the camber and sheer of the boat and glued down using West epoxy in between of course. We will then lay on a veneer of the original teak to keep the traditional look of the boat, put the cabins and hatches back on, and the fittings that we’ll have carefully labeled and taken pictures of where they are located before removal.