Ingot molds for Tally Ho's internal ballast- Final shapes plus a bonus project.

Here's an easy watch of the fabrication for the two final ingot mold shapes for Tally Ho's internal ballast. As you all now know, Leo and his crew are on an accelerated timeline to get Tally Ho in the water. Not quite sure of how tight a schedule but sensing that it was more than a little urgent I did my best to get these done and into the mail. There were a few comments on the Prototype video I put out a couple weeks ago about engraving or adding material to the mold to cast the boats name into the ingot which I appreciated. I had asked Leo about that when he first sent me the drawings and he indicated that it might be kind of neat to have TH 1910 in a couple of the molds. I took a couple of tries with different methods but wasn't happy with anything given the time I had. I also felt strongly about leaving a mark that would be hard for Leo to opt out from if it didn't meet his expectations so after mailing the last set of molds I found a bit of time to create a solution that still gave him an option but only if he chose to use it. I probably would've spent more time on it if it was available but I felt timeliness was more important and that I should get it directly into the post as well. It's his to use or not with no concerns or obligations on my part and having been massively overbooked this winter I just enjoyed the time in the shop that I spent making it.
Although this might seem a little backwards given the size of Sampson Boat Co's platform I realize that I do have a small but steadily growing platform here that you all have created, and if you enjoyed this video and you haven't already that you might consider subscribing to the Tally Ho project here ​⁠‪@SampsonBoatCo‬ and also consider looking at his Patreon here; / sampsonboatco It really is an amazing channel and the quality of his videos are truly spectacular. You won't be sorry that you did.
As always, thanks for watching and hopefully I'll see you all with my next video.
Thanks,
Jake
#tallyho

[@ShredPile]

So quick update; a few days after I sent the last batch off in the mail I got an email from Leo giving me a heads up on the timeline of things and I immediately offered to come up and help with the ballasting. He took me up on the offer right away and we quickly hatched a plan on the order of operations and the next morning I was on my way North. I stayed for two days and poured and modified ingots until we ran out of lead and they ran out of room to put ingots. I'm super glad that I went for several reasons, number one it's filthy work and it seemed that everyone had had a turn at it and everyone was c o m p l e t e l y over it. I was able to just dig in and work without interruption. Number two, a couple of the simpler molds sprung leaks thru a capillary action at the junction of the bottom and the end well outside of the mold cavity itself and it was just a small weld about 6mm long to fix it up (It would've been horrible to hear about it from almost 200 miles away and unable to help:) For me it was a real treat to be able to help in this fashion, Leo and his crew are a great group of folks of course but the real star of the show is Tally Ho. She is absolutely breathtaking. I had a few moments to stand a look down the length of her deck and it sort of stunned me into silence with just how incredible it really is in person. I think we all are richer to have been able to follow along over the years on this project. Oh, one last thing. Driving away from Port Townsend I realized that I had completely forgotten about the branding iron and in retrospect the only place it would've been appropriate was on an ingot so it is what it is and I already had the video done so I left it as it was. -Jake

[@Chr.U.Cas2216]

Dear Mr. Rosenfeld. 👍👌👏 Very "weld" done, Sir! I absolutely understand that you enjoyed helping out. I would have loved to help when Tally Ho was still in Sequim. But unfortunately there is this big pond between the project and me. Best regards, luck and health in particular.

[@ShredPile]

@@Chr.U.Cas2216 Thanks for that!

[@Chr.U.Cas2216]

@@ShredPile You're welcome, it's my pleasure. Thanks for replying and especially for giving a heart to my comment. I totally appreciate both very much. Sincerely yours.

[@josebembibre7298]

Great job!

[@paul0730]

I think Leo and his crew have a unique ability to bring out the best in each other and anybody to watches their craftsmanship. This video is the same- bringing your best work and best attitude all the time. There is a lot of satisfaction in simply doing a good day’s work. So proud of the Tally Ho project and how it has had a positive effect on so many people. It’s worth it! It’s not for $$$ it’s for something beautiful to share.

[@Boatbuilding48]

Leo has a nack for finding the right people for the right job! Very informative and well done!

[@forgetn]

You’re the one who made the molds…amazing Tally Ho was using them today in their videos. Nice job

[@ShredPile]

Thank you!

[@danbreyfogle8486]

I was surprised to see you molding ingots on Leo's last video. What a privilege to help out on this project. I liked the stamp even if it didn't get used.

[@ShredPile]

Thanks Dan, I felt the same way about being able to help. Those two days were exactly my favorite type of vacation:-)

[@4englishlies875]

I saw that this was for Leo and just had to watch, glad I did! The fabrication of the molds , not all that hard but you can see the skill and pride you take with your work. I will have to check other videos you have done. Very happy that I saw this video, and love the pride you take in a job.

[@ShredPile]

I'm glad you found your way here too and thanks for the nice compliment. What an amazing project Tally Ho has become!

[@trep53]

I don’t know why but I enjoy watching welding. When I got out of high school in ‘71 I wanted to learn to weld so I got a job at a local fabricating shop/factory. They had me grinding welds all day long with a grinder that was very heavy.

[@ShredPile]

'Miscellaneous metal detailing' is that job title now I think :-) Hopefully they let you weld a bit before you moved on. Handy skill to have. I appreciate you checking the video out:-)

[@paulbadger6336]

Hello Jake, I really like your style and envious of your energy. I have followed Tally Ho since the beginning and must have picked up a link to your channel. I have been binge watching your house build videos and just today realized that you are one and the same. Not realizing your connection with Tally Ho. You are a fascinating individual and at 75 , versed in several fields of construction, manufacturing, and engineering I feel qualified to pour on the praise. Thank you for sharing your time and talent. 👍

[@ShredPile]

Thanks for that Paul, that's really nice of you. I'm really glad you found the channel, there's such a variety of fun stuff coming up that I'm not sure how I'm going to film it all. I'm excited to share it all nonetheless. Should be a good summer!

[@Chr.U.Cas2216]

👍👌👏 Thanks a lot for making teaching explaining recording editing uploading and sharing. Best regards luck and health in particular.

[@Mad-Duk_Machine_Werkes]

When I was a kid, My dad and his cousin with a welding shop made up a hinged mold for casting solid lead wedge-shaped bass boat anchors. Since by day he was a 100-Ton Tug Boat Capt, he had my uncle run a bead of weld on the mold that Spelled out "Capt. Paul" - and proceeded to cast a few dozen lead bass boat anchors- they sold like hotcakes- we made batch after batch of them, some guys bought two and 3 for their boats to hold position Bow and stern, etc - Point is, you couldve ran the words via Weld-Bead into the floor piece of you mold and when they turned them over to knock out the ingot the letters and numbers wouldve been deeply cast in

[@ShredPile]

I like the sound of the hinged mold. Pretty cool. I was really hesitant to leave anything less than something perfect in the bottom with no way for leo to not be stuck with it so the brand was the best I could come up with. It's all good, no one will ever see the ingots and it's such a small part of the overall project considering all the giants that have stepped up to actually make the boat that I think everything worked out the way it was supposed to in the end :-) Thanks for checking out the video!

[@ethankincaid9022]

Awesome, the KZbin crossover I didn’t expect, love it.

[@justjoe7313]

Tally Ho brought me here :) Cheers, you have a new subscriber :)

[@ShredPile]

I appreciate that!

[@TheMikesylv]

Same here

[@robertsimmons3556]

Good change up post Jake! Just read your below update. What a rare opportunity to be part of such a project. You write and express your impression of Tally Ho perfectly! Great job!!

[@ShredPile]

Thanks Robert, It was really neat to see what a talented crew he has and the job they did. So amazing.

[@TomokosEnterprize]

These weights worked out perfectly. The ballast has her sitting perfectly in the salt at Port Townsed. You naild them bud. She still needs a bunch more work from all those tallented hands.

[@roblescurbappealconcrete]

Hey Jake Hope you are doing well. Always a pleasure watching your videos, even though I’m a little behind. You’re a very talented person, and I appreciate your hard work and attention to detail. Keep up the awesome work. Have to catch up a little. You’ll hear from me again, I know that any comment I make is good for your channel. Take care. 🤙

[@acraftman2823]

Been following you on the house since you started the lower level framing and saw you make the test ingot so I left a shout out on Leo's channel I know he's probably sweating ingots himself but was glad to see him give you a mention.

[@ShredPile]

Hey super cool, I appreciate that. I spent two days up there this last week melting lead to meet the deadline and then had to get back to work so I missed most of the craziness on launch day. It was really neat to see the boat in person. I saw it a few years ago dropping off another project but so much has changed. Thanks again!

[@ronald2811]

very nice unique stamp!

[@benlund3905]

You got some allistairc music going on at moments. I am also here cause of the tallyho thing. Am contractor in pdx tho. Had a couple clients in hillsborough. Only work se pdx nowadays. Got an older marvel. Need to replace the feed friction thingies. I do steel railings,welding also. Hate the gun/feed sleeve fail.

[@ShredPile]

Hey I watch that guy too from time to time! Glad you're local to me here and have the same taste in saws:-) Do you know about Darcy saw llc? You can still buy every single piece and part for Marvels from them including the 'approved' corks and assembly grease (not that normal ones wouldn't work) its a good resource anyway. check them out, they'll send you a catalog for whatever model you have. I have an older marvel too that needs cleaned up and converted to single phase still but there's a long list to finish before i get to that:-)

[@benlund3905]

@@ShredPile yeah. Got some parts from them. Cost more than the saw did. Cant believe they providing all the parts for the historical line of these saws. My kind of company.

[@gersilsilger6374]

Great Job!

[@Michael-he7xn]

Great work!

[@jefftabor595]

Quality work

[@markchodroff250]

Great job !

[@wayneclark7048]

Great job, keep up the videos. 😊

[@dadbrad852]

I could see that brand coming out at a crew party. Sailors will be sailors.

[@ShredPile]

I agree with you completely. Years ago I made a logo brand for a group of wild men that put on bike races. It was a bit larger than a new roll of electrical tape and made it's way out of the truck and into the bonfire one night and was used on dozens of things until someone started sizing their own calf up..... Luckily some sober soul wisely managed to get it put away for the rest of the night:-)

[@guypehaim1080]

One way to put the lettering into the lead ingots would be to weld bead the letters onto the inside of the bottom of the mold in reverse so the letters would be cast with the ingot.

[@currentbatches6205]

29:40 - Can't beat MIG for inches of weld/time. 46:42 - Bet a lot of folks would buy one of the molds to establish a 'connection' to Tally Ho.

[@ShredPile]

Hey thanks for checking out the video! I wonder what Leo will do with the molds, I’m sure the flat pan ones will get a lot of use in the boat yard and maybe the stepped ones will as well, who knows? :-)

[@MUDNROCKS]

Easy to be a smart arse after the fact but I was a Plumber/Roofer/Gasfitter/Drain layer in an earlier life before Engineering and another contracting company mate, and I'm old enough to have done some old school lead work and lead burning. So for my money you'd have been better smutting up i.d. tags for the bottom of the pans at casting or making the branding iron with a more robust backing plate and no handle then pressing the name into the ingot cold. Casting it in would look more 1910's and pressing it in more modern and accurate, you know this I'm sure. By the way that is a very nice saw, big and ugly but still very nice and one day you should tell us about how you happen to have it ... the way you think and what you do, how you do it, I've watched closely and you are much more than just a carpenter with a bunch of equipment and tools n a big lean-to shed. Cheers mate I appreciate your good work.

[@ShredPile]

Yeah, I had plenty of other ways I would've liked to do it but it was of those jobs that the due-by date was 3 weeks before I got asked to do it in the first place:-) I really like the cold press idea too, I hadn't thought of that. I really would've liked to have had some cnc letters milled to tig to the bottom of the mold so it looked perfect but just no time. No excuses but I've been working 7 days a week for a couple months now and the day I built the bulk of the stepped ones started in the shop at 4:30am , did a full day framing and then finished in the shop at 8:30pm before coming back out before bed to wrap them up to ship I was gassed. Given more time they all would've been polished wonders but it got the job done anyway. Thanks for the kind words too, they mean a lot to me.

[@TheMikesylv]

Did you make a different mold for every bay ?

[@ShredPile]

No just two shapes But Nic modified some of them by trimming down the notches on the bandsaw to make them fit in the narrower bays. He was decidedly nonplussed about that part of the project:-)

[@tonybrock5288]

I had assumed that the 3 degrees relief was for the mold to release the lead only? It wouldn't come out easily otherwise. As far as I know the ballast was all laid "flat" and not in any kind of ark.

[@ShredPile]

I initially assumed that as well, but after the step version got redesigned upon delivery and testing of the prototype, most of the angles changed to 2° with the exception of the long faces which remains 3° in the direction that would allow them to arc. That’s all I know, and since we only saw a fraction of them installed in Leo‘s video I personally don’t have a reason to believe that it’s not. That said, it doesn’t really matter to me either :-) sometimes small jobs just go that way and you make a part and put it in the mail. I do appreciate you checking the video out and interacting with it because it all helps :-)

[@tonybrock5288]

@@ShredPile Ah, I see they did follow the curved shape of the hull horizontally along. And they were fitted tightly in between the ribs, so they did need a bit of an angle. Thank you for your great work helping them!

[@Z-Bart]

Carbide blade on your bandsaw?

[@ShredPile]

No but I didn't feel like taking a bath in coolant right at the edge of the saw :-) It's a long blade at 14'-6" so it can soak up a little abuse i guess.

[@jamesmarsh1831]

It would be easier and quicker to take the stamp and put together with the ingots under a hydraulic press to stamp the letters and numbers in and you wouldn't need to use any heat.

[@ShredPile]

I completely agree, another commenter suggested the same thing and I indicated that that possibility had never even occurred to me. It’s a good one and I love it. There’s a lot of things that I would’ve done.if I had even a little bit of notice before the project. I probably would’ve had a small plate engraved with raised letters to place in the bottom of the mold and create a recess in the ingot. I had less than five weeks from first contact to return a prototype, have him test it, indicate changes and then make the full run. That five weeks encompasses the last ingot going into the boat. I do appreciate you checking out the video.

[@user-tj3zt5jw7l]

И чтто это было?

[@jimrobcoyle]

TH 1910