Tally Ho Capstan Project: Machining the Internal Gear and Test Fitting the Chain Gypsy

Tally Ho Capstan Project: Machining the Internal Gear and Test Fitting the Chain Gypsy
Support VintageMachinery.org on Patreon:
/ vintagemachinery
Make a one time donation to VintageMachinery via PayPal:
www.paypal.me/VintageMachinery
Please Visit: www.vintagemachinery.org
Sponsored by:
American Rotary Phase Converters
www.americanrotary.com/?sld=k...
Use checkout code "Vintage10" for a 10% discount on all AD, ADX and AI converters!

[@heinvosloo45]

What I find particularly fascinating is how the "old crafts" were used in the restoration of Tally Ho. And in addition to the work on the boat, it includes the metal working crafts like fitting and turning and casting of the broken parts. In a word of computerized manufacturing ( which I love) seeing people produce things "with their hands" is particularly satisfying.

[@amunderdog]

Jay Leno talks about; "What was made by hands, can be repaired/rebuilt by hands".

[@GhostOfCorkey]

Aside from the grinders, chainsaws and fork lifts….

[@TomokosEnterprize]

Many processes have been done the same way for thousands of years.

[@robertweeks4240]

well said i can't add anything better... love your insights here

[@brownhues]

​​@@GhostOfCorkeyThat's a disingenuous comparison. The people who made Tally Ho had tools to help the humans that made it. The tools are just more efficient now. It's not like Leo is using AI and additive printing to restore his boat. You are being a See You Next Tuesday.

[@wdhewson]

"Dirty Hands......Clean Money" is one of my favourite bumper stickers. Keith qualifies !!

[@petegraham1458]

That’s a nice collaboration of excellent talent to restore this important and impressive bit of maritime history! I applaud all of those who have contributed their skills to make this a reality!

[@bobh64]

Amazing the communication distaances and teamwork this project introduced.

[@wollaminfaetter]

Following this long and complicated tale of the re-creation and modification of the capstan for Tally Ho has been (is) really exciting, and a prime example of what KZbin can do. The combined efforts of many different KZbinrs have made it a journey into forgotten crafts.

[@davidrandle8093]

As a lifelong recreational sailor and a longtime subscriber to your channel, I'm truly enjoying the merge of your machining expertise with a marine application! Lovely collaboration between you, Windy Hill, and the UK engineering firm. Wonderful to see it all coming together.

[@TheManWith2FirstName]

You could drill and tap the gear face so jacking bolts can be used to make removal easier.

[@CameronMcCreary]

Good morning all! I have been looking forward to this presentation.

[@jonscott8843]

Keith, I'm in the UK and have been watching you, Leo and Clark Easterling (and his many helpers) for years already and am so so pleased to see you all, -with Dave the Pattern Guy- all get together and pool your incredible skills to make this project come together, and like a few thousand others, I am eager to see the whole thing finally finished. I am sure it will be a beautiful thing to behold. Love your videos.

[@drspock3454]

Why is dave the pattern guy crossed out? Is there some drama?

[@joshua43214]

@@drspock3454 From listening between the lines, so to speak, my understanding is that the inside of the pattern was not smooth enough for how little draft it had, and the core parts were sized so that the cope was far too heavy. If the core parts (the whitish parts of the mold if you watched the video), had been about half as thick, the cope boxes would have been smaller, making it much easier to handle. They really only needed to be about 3/4" thick, not the >2" that they are. That probably added at least 100lbs to the mold. One of the other guys also mention he had to spend half a day smoothing out the interior of the mold, and there was a few comments about spending hours taping on it trying to get it to come free. It was clear from Dave's videos that he was pressed for time, and I think that caused a lot of problems.

[@davidc6510]

@@joshua43214 It should be noted that Clarke nearly had a perfect part on the first casting. It came out a little short on the thickness on one side which was not up to WHF standards. Each time (6+) the pattern was rammed with sand it would scratch, scour, and abraid the mahogany which would make the removal from pattern from the sand more difficult. During the final pour the extra attention to make the pattern surface smooth paid off as well as the other adjustments to make it a success. Dave Clark also took some time to add draft and radii to the pattern to improve the original design. Overall the road to get a successful part had some bumps in the roads and things could have been done better especially if there was intent to make more than a one off part. Pointing a finger of blame at Dave Clark is in my opinion a bit unfair.

[@MrKotBonifacy]

@@drspock3454 No, it's just this weird YT "editing" toolbox - whenever you "insert" a word or a sequence of them WITHIN normal dashes, AND without any space between the dashes and the immediately following/ preceding word you get this unexpected "cross-out" effect. In order to avoid this you have to insert a space between the dash and the word, or maybe use "long" dashes (not sure), but then English has these peculiar "rules" about using this or that dash for this or other purpose (apparently it's wrong to type "red-haired", you have to use a long dash, here, red-haired but then not being native English speaker I'm not 100% sure about this). FIY: underscores (_) italicise a word: _example_ - again, no spaces between the "coding character" and the word - also, other punctuation marks or line feed/ carriage return interfere with this "feature" - place a comma or full stop just next to the underscore, and you'll get this: _example_. Somehow quotation marks do not interfere with it: _"example"_ Asterixes (*) turn the word within them into bold text (semi-bold, I'd rather say): *example* - again, "as cautioned above". Apparently you can mix them too, but you have to "mirror" the sequence: _ * word * _ I introduced spaces intentionally so it'd show how it's done, here's the real *_example_* And the cross-out - -example- So, this is "why". And, oh, by the way - in case you're NOT interested, just ignore it altogether, and just don't read it ;-) Also, I can't "preview" this, and somehow my "examples" where I tried to show the coding, NOT the effect (so I made them "wrong way") appear messed up - they are neither "the effect" nor "the coding". But then it's YT's _advanced features_ for ya, unfortunately.

[@joshua43214]

@@davidc6510 I did not point the finger at Dave, the OP did in a passive aggressive way. I just explained the issues with the pattern to another who asked. Even in the first video, you could tell Clark was unhappy with the pattern.

[@walterplummer3808]

Good morning Keith! It is coming along nicely. Have a great week!

[@marlobreding7402]

Good morning from Eugene, Oregon. Saw the successful casting of Tally Ho's winch. I'm looking forward to seeing your part.

[@ccswede]

Mr Rucker has the capstan and will be machining that also

[@mwrcrft]

I love it when a plan comes together. Figuring the reason for the three jaws to not center the piece at first try must have been one of those ,well ain't that fancy moments.

[@bulletproofpepper2]

I should have been ready but yes I’m gobsmacked again, watching your videos is always fun. The gobsmacked the amount of people working on different parts of the project and parts are fitting together perfectly. The tally ho project has been a big one and so grateful you are able to help out and bring your masterful metal craftsmanship into it.

[@tomoakhill8825]

Keith: I have been watching the Sampson Boat Co channel for six years. This is so exciting to see. I have been subscribed to your channel for about as long. To see you two working together is wonderful and a true joy. I am so stoked to see this get done.

[@recycle343]

Good morning from white Mt. NH. I .look forward for Keith and how he solves problem.

[@asakurad]

Love your precision and calm delivery.

[@rexmyers991]

Keith - I am so impressed with all the work you do. You seem to be everywhere. And, I understand you still have a full time job.

[@philipbrailey]

Can’t wait till it’s finally finished.

[@user-us4dm6qp2i]

I'm always held in great wonderment at the machining skills and scale that went into producing the war machinery of WWII. Makes my 1937 South Bend equipment seem laughable. Thanks for the well produced videos.

[@peterclancy3653]

You can laugh, I have a Drummond round bed lathe built in the 1920s, still does the job for me and the Drummond company in England sent me a manual on request. I have only owned it for 6 years but can turn to size and cut imperial and metric threads which is about the limit of my skills. Love watching these highly skilled people doing this work. The greatest generation!

[@dannyl2598]

Thanks Keith. Such a close fit for parts that started off world's apart.

[@mitchmitchell515]

Cool to see an old school engineer knocking it out the park

[@markpalmer5311]

Really nice to see these engineered components being installed into such a cool part of Tally Ho.

[@dwaynekoblitz6032]

I'd swap the brand new 65K lathe at work for that beautiful vintage machine. That's truly cool. Frag-eee-lee! It must be Italian! It's a grand award! The correct person was chosen for this project. So calming to watch a master machinist on an old machine. I once ran a WWII surface grinder that was as big as a VW beatle. Still cut a thou no problem. Thank you so much for helping Leo. I've enjoyed all of the capstain videos on all the channels absolutely just as much as Leo's videos. So damn good!!

[@seancollins9745]

Next time make some soft jaws out of aluminum next time you need to grab a gear. A big set of pie jaws. Turn them to size closed then you'll fix the concentricity issue before you start and hold the part with less distortion. I say this as someone routinely making parts 100s at a time holding tolerances in the 1-2 tenths range

[@Hoaxer51]

Keith should make a video of making a set of those, it would be a quick video but fun to watch.

[@petemclinc]

Soft jaws or at least some contoured aluminum pads to prevent chewing up that soft bronze.

[@melshea2276]

Happy What Ever Day it is!😊⚙️🛠⛵️👍👍👍👍✌️

[@larrydeforrest5744]

Great job. Hopefully I'll be able to see your work someday on the Tally Ho. I live about 75 miles away fron Port Townsend.Thanks for all the work you do,Love your channel.

[@shogun666able]

Great to watch a tradesman that knows his game inside out and has the gear to do it.

[@garybrenner6236]

You must be kidding!

[@cliffludo6860]

Thanks Keith, a really interesting capstan project !

[@stevewoodard527]

Thanks to the playlist Keith has set up for this project, it was easy to go back and review the disassembly and initial machining for the gear to fit against. Good review, at least for me.

[@ccrider5398]

Dad, Mom, older brother, and I have all worked in shipyards as rigger, welder, boilermaker, and machinist. It's always good to see nautical content on the channel.

[@jensschroder8214]

It fits in nicely without wobbling. Great job. But salt water is corrosive. That's why there should be a layer of paint between the cast steel and stainless steel. Blank on blank will corrode with salt water ! Or glue it airtight and watertight.

[@tommcallister7647]

While I know absolutely nothing about machining, I suspect that will be achieved by the bedding compound that Keith mentioned.

[@josephmagedanz4070]

Good to see everything coming together now...should work great. Thanks for sharing.

[@TheUncleRuckus]

Coming along nicely Keith. 👍👍

[@fepatton]

As Maxwell Smart might have said, “That’s the second-biggest micrometer I’ve ever seen!” 😂 Love seeing these operations done old school. Excellent work as always.

[@billmeldrum2509]

Hey Keith… fascinating project. Fun to marry the old with new. 🇨🇦

[@Laz_Arus]

One aspect of this winch restoration project I've been wondering, is whether the channels involved are charging a fee for their work, or simply volunteering, realising they will benefit from additional channel views because of the huge following Tally Ho already gleans. Regardless, it's great to see the technical expertise all come together for such a great cause. 👍

[@KoenKooi]

Or something in between, where expenses like shipping and materials are covered, but not labour.

[@tomrobertson3236]

I feel that costs are charged but the channels get more shared subscribers

[@davidyendoll5903]

Let us thank all the help Leo is getting to restore Tally Ho ; I sometimes wonder if she will be better than 'as new' when she gets launched , I am not sure .... , but we get to see crafts , skill and materials in the restoration and hopefully the sailing later on . Brilliant . There is another youtube channel which shows a castle being built with the tools and materials of its pretend period in history with the same intention .......take us back in time and maybe even relearning skills . Respect

[@petemclinc]

I doubt these guys are doing this gratis, too many hours, needed tooling and materials.

[@steveparker8723]

I have watched the Tally Ho channel for several years off and on. It's neat seeing all this come together from several different disciplines/crafts etc.

[@normmcrae1140]

MAJOR Progress! Can't wait to see how it all comes together!

[@waynephillips2777]

This is a great series to be able to watch! Thank you!

[@guypehaim1080]

A consideration with this ring gear is that the tooth engagement must be concentric with the center of rotation otherwise the pinion and ring gear engagement will vary and that will not be good for the longevity of the gearset.

[@davidyendoll5903]

I wonder how accurately made early winches actually were ? Clang clang clang knock clang

[@guypehaim1080]

That might be so, but they weren't electrically driven through brass gears. When that windless was first installed on Tallyho's deck, it was human driven.@@davidyendoll5903

[@petemclinc]

I was wondering if that ring gear needs to be clocked a certain way or if the drive gear makes up all the adjustment.

[@ararmour]

Keith, absolutely fascinating stuff... Lovely work.

[@jjlpinct]

Beautiful!

[@DarylSaunders737]

My God what is that Capstan worth ??.. The skill and engineering from all you guys is amazing !!.. On a project that has captured the imagination of so many people in its own right.

[@mauricekeithjohnson2598]

Having 50+ years as a boat systems builder, mechanic and technician, I'm wondering same thing ! I also have followed Leo and TallyHo since day 1.

[@DarylSaunders737]

@@mauricekeithjohnson2598 I would be looking at annual yearly full service, due to the fact of the composition of the metals used. Plus the interaction of salt water and electricity.

[@TomokosEnterprize]

I just saw the final post from Clark and friends. You can feel the want in the air eh, LOL. They all worked hard on a pour that just never happen there eh. Well done fellas !

[@StevenEverett7]

As always, great video Kieth!

[@brianlouishaddock4551]

Excellent work Keith, as ever you never disappoint us with your amazing talent.

[@erichwoodall2897]

That chain fit up was sick. Nice tolerances

[@jameshamre8778]

Keith, this episode is absolutely mesmerizing! Great job as always. Appreciate your sharing the details of old school craftsmanship.

[@prototype3a]

That's a pretty spiffy 3-jaw chuck. I don't think I've ever seen one quite like that.

[@mattsmith9216]

Great job by both of you.

[@drop_dtuned6167]

So exciting, the pieces are coming together now. Wonderful, just wonderful!

[@amateurshooter6054]

Thanks Keith

[@patrickradcliffe3837]

2:48 thank you for dropping the audio level hammering those pins out!

[@davidc6510]

Great work Keith. I enjoyed the video and look forward to the next installment. Thanks for sharing.

[@donkultgen4643]

I'm here for the tape measure tips and tricks.

[@CothranMike]

Funny you should mention that. While working with a rough Machinist on catwalks for the Gantry crane manufacturer here in Huntsville for what are the launch sites there at Kennedy we had to hold a 32 of an inch tolerance over 115 and 3/4 ft and since the tape measure he was using was only a 50 footer and error creep was a factor, we use the same tape three times to measure the length, marking as we went. To prevent any compound errors I use my 25 ft tape in the other direction and the shop lead had a 200-foot architectural fiberglass tape. Needless to say it was an interesting proposition and everything worked out okay unfortunately for the inspectors they didn't have any tapes.

[@edsmachine93]

Thanks Keith. Nice work.

[@rheffner3]

What a fantastic job you are doing. Can't wait to see it on Tally Ho.

[@Nick-ye5kk]

Excellent video, its looking good.

[@SciPunk215]

This is looking good. It will be used for years to come!!

[@frankerceg4349]

Thank you Keith!

[@quinntalley1681]

Spectacular!

[@stevenclaeys6252]

Thank you for another great video. Cheers

[@annteve]

Amazing!

[@rick91443]

Thanks. Enjoyed watching...

[@zevakikel]

Thanks Keith for sharing!

[@kevinwayne7546]

cool project his boat has been an amazing project.

[@steverobb5360]

Another great video! Thanks!

[@ladamyre1]

I'd have been more interested in how true the inside gears were than the outside diameter. Something about trusting the manufacturer of the gear to have those teeth true to the outside of the thing. I'd have been focused on making sure those gears were exactly centered by setting up the gear by reading the run-out on the inside.

[@SPUDHOME]

I agree 100%

[@petemclinc]

Yeah, he should have checked the concentricity of the ring gear I.D. also.

[@propulsar]

Nice job!

[@rozzab6993]

Please be careful that the capstan doesn’t roll off the table. Love the videos!

[@allobject]

Well done... 22:30 - no issue doing things the old fashioned way... shows the understanding what is going on.

[@Topsailor157]

When the Navy taught me machining they wouldn't let us use the machine dials. We set up dial indicators for everything. That was in 2005.....

[@user-ht1yp9qn6e]

Fasinating and impressive

[@markfoster6110]

Looks great . Great job .

[@waynes.3380]

Keith it's coming along nicely.

[@jeffreytan2948]

Leo has made such a reputation for himself that everybody brings their A game whenever they are involved in the Tally Ho project.

[@charlesseymour1482]

I love the A-game.

[@6NBERLS]

Most excellent.

[@OldSkoolF]

Great work!!!

[@billgolcher2537]

Awesome job love that lathe

[@elsdp-4560]

Thank you for sharing. Very nice.👍

[@kencannuck]

Nice work!

[@nikolaslarson6891]

This is art. No errors allowed here.

[@Ibh111142]

This is so interesting thank you

[@timf6916]

Nice, good job.

[@tomk2165]

The capstan may easily reach 150F in the tropical sun. The differential expansion of about 0.005" will put the thin cast iron skirt into tension, risking cracking.

[@nathanchalecki4842]

I hate being an arm chair machinist, honestly, but I just don't like that thin skirt and the thin material that joins it to the shaft. Everything tells me it's a liability. I know I am probably very wrong as I'm definately not capable of understanding the forces involved during use.

[@petemclinc]

That thin wall does look a bit wimpy...

[@tuberNunya]

Not a lot of tropical sun in either Port Townsend or England.😁

[@floridaflywheelersantiquee7578]

Thanks for sharing

[@bigredc222]

Good job.

[@jjacek74]

good job!

[@zazaz44]

excellent. great chanel.

[@richardbrobeck2384]

Nice job on the maching !

[@kdel9776]

Thanks bro

[@1963jesse]

Nice Video!

[@johnlennon335]

I wonder about galvanic corrosion with three dissimilar metals and salt water. There should be a replaceable sacrificial anode designed into this or some other solution to this problem.

[@edwardtimberlake4646]

I am so impressed by your contribution and skills being applied to the capstan rebuild and modifications. As others have mentioned it is really nice to see all who are involved in bring it back into life, and the co-operation across many locations and between the USA end with that in the UK. I guess that applies to quite a lot of work going into Tally Ho. I do have one concern and that is, what finishes are being applied to avoid or reduce rusting of parts, internally as well as externally?

[@KennyP88]

What a fun project. Wish I could be helping.

[@politicalGRAFFITI]

sweet!

[@MikeBaxterABC]

4:03 !! Nice one .. One punch knockout!!! LOL .. Nice machining makes it easier!! :)

[@jimrobcoyle]

Hail the algorithm! #TallyHo !

[@paulputnam2305]

Awesomeness Extreme

[@TomokosEnterprize]

Hi Keith and all. An adjustable 3 jaw chuck ? WOW, I really want one now. I think we all love the ease and looks of working with brass and bronze. Great fit on that brass gear. Too bad it will never be seen. Has a color been chosen or will it stay battleship grey ?