The Rebuilding of the 6 Metre Yacht “Merenneito”

NAME: “Merenneito”
CLASS: 35′ – 6 Metre Racing Sloop
BUILT: Hango, Finland, 1927
OWNER: Lars Lindblom, Helsinki, Finland
PROJECT: Remove and replace the stem, keelson and counter-horn timbre (sternpost). Drop the lead ballast, then re-attach to vessel with new bronze keelbolts. Remove and replace 113 (of the 128) steam-bent white oak ribs, both full-length sheer clamps and every mahogany hull plank. Replace all of the bronze floor frames. Replace approximately half of the deck beams along with all of her deck planking. Build a new cockpit (to match original 1928 layout), new mast step, new coamings and new floorboards. Sand and finish the entire vessel (inside and out) with 7 coats of Epifanes varnish. After she was shipped back to Finland, the customer had new spars, rigging and sails made. The final coats of salt water antifouling paint were applied to her bottom just prior to launch.
“Merenneito” arriving at Woodwind Yachts in 2005, after spending many years safely tucked away inside one of our storage buildings.
With the garboard and broad planks (lowest planks) removed, we can now see the extent of deterioration to the lower ribs, keelson and deadwood.
Over a heavy mould of plywood, the new keelson is laminated to the exact shape of the original. The vessel in the foreground is a 14′ Aykroyd.
The transom framework has been removed and the new framework is being shaped to fit. The two large holes will be drilled later.
The counter-horn timber (sternpost) has been carefully removed. You can see two short planks on the port side just below the waterline. These cover over a previous outboard motor well which had been cut through her original planking.
A heavy plywood mould was constructed to the exact shape required. Here, the new deadwood and counter-horn timber are being laminated together and clamped into the mould while the epoxy cures.
The new counter-horn timber is removed from the mould and shaped to the boat. The pockets for the rib ends have been notched into the new piece.
The original stem, which had been repaired numerous times over the years, has now been carefully removed. The new stem will also be laminated overtop a plywood mould, then fitted and scarfed to the new keelson.
With the new backbone (stem, keelson, deadwood and counter-horn timber) installed into the vessel, the systematic process of replacing the required 113 steam-bent ribs begins. Here, one of the new ribs has just emerged from the steam-box and is being bent into the hull.
The rib is being pushed and tapped into position while a man on the outside of the hull on the floor is clamping it into place. This process should take less than 10 seconds before the new rib begins to cool off and harden. One full-length plank each side at the waterline has been removed for clamping access.
A series of straps and ropes are used to hold the protruding ends of the new ribs in the correct position while they harden and dry over the following weeks.
The new ribs at the mast step were laminated together for increased strength in this area of the boat.
A few of the original ribs in the vessel’s bow were salvaged. Wooden ‘bungs’ are epoxied into the old fastener holes. The ‘bungs’ are cut flush, then these ribs were stripped and varnished prior to being reinstalled. Also shown in this picture are four of the new ribs which have been removed for varnishing.
The bottoms of all the new ribs have been sealed then set into the rib pockets cut into the backbone with 3M 5200 adhesive and screwed into place. The backs of all ribs have received three coats of thinned varnish prior to planking being installed.
With the new backbone and all ribs installed, “Merenneito” is ready to be reunited with her lead ballast keel.
With her keelbolt holes all drilled and sealed, she is shown here being reattached to her ballast keel with new bronze keelbolts and 3M 5200 adhesive.
The new starboard garboard planks have been trial fitted to the lower hull. Three runs of full length planking are trial fitted to each side of the vessel at a time. They are then removed, varnished on the inside and edges, then permanently reinstalled onto the hull.
Due to the severe bend in the vessel’s lower hull, many of the planks had to be steam-bent into position. This eliminates any possibility of splitting the new planks, and reduces excessive pressure against the new ribs.
All hull planking was scarfed together into full length planks requiring no interior butt blocks. This picture shows one of the step scarfes being cut.
This picture shows approximately one-third of her planking has been built and permanently installed.
A view of the bilge just prior to the new lower planking being permanently installed. Most of the original planking is still on the vessel at this point.
Patterns were made as required, then new bronze floor frames were cast. (Slightly heavier than the originals.)
With the new bronze floor frames and the lower bilge planking permanently installed, we are preparing the bilge for a coat of varnish.
The original bronze chain plate assembly which is recessed into the planking, is found to be in very good condition.
This picture shows the upper starboard hull plank has been meticulously cut and varnished prior to installation, allowing for chainplate recess into the backside of the plank.
The original rudder is sound enough to repair and re-use. With some scarfe and spline repairs done, it is now fitted to the boat.
Prior to the new decks being installed, the inner hull is sanded and the final coat of varnish is applied.
The new long-length Norwegian pine decking (same as original) has been milled. The undersides and edges are sealed with several coats of varnish prior to installation.
The new mahogany covering boards have been built and temporarily installed. You can also see the new inner transom and frame prior to the final coat of varnish.
The new deck planks are fitted both ends to the covering boards, sealed and installed. The deck planking is pre-drilled, then edge-nailed together as well as fastened to the deck beams.
After the decking has been completed, the mahogany covering boards and king planks are removed. Here, the cloth is draped over the new decking, prior to applying the epoxy.
The hull is masked up for protection from mess, then four coats of epoxy (along with the cloth) are applied to the new decks. (Originally the decks would have been canvassed.)
After curing, the decks are washed and sanded smooth (ready for primer). Here, the covering boards and king planks are being permanently installed in 3M 5200 adhesive.
After the covering boards, king planks and hull have been hand sanded for the final time, they are all stained. Here, the 4th coat of varnish is being applied to the hull.
Prior to staining, the cove stripe was cut into the sheer plank with a router. Here, the cove stripe is being painted in gold leaf, prior to further varnishing.
This picture shows the finished deck undersides (with grooves matching the originals), the upper hull with recessed chain plate assembly, along with some polished bronze deck / hull frames.
Approximately 10″ long mermaids have been carved out of wood to match exactly the originals. They are painted in gold leaf and will be mounted on either side of the hull, forward of the cove stripe when she arrives back in Finland.
A sturdy cradle is built, capable of safely transporting her as deck cargo aboard a freighter, back to Finland.
The completely rebuilt “Merenneito” emerging from our shop for the first time. She is being transported overland to Baltimore, Maryland, where she will be loaded onto a ship bound for Finland.
“Merenneito” along with the happy crew at Woodwind Yachts. Happy to complete this exciting project – yet sad to see her go.
Now safely back in Finland, a few details are being worked out and trial fit with the new aluminum mast and rigging.
The owner has now applied the salt water antifouling paint, and she is being lifted ready for launch!- What beautiful lines!