Exterior Construction:

Cockpit
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The cockpit was the first part of the boat to be constructed. The hull was still being torn apart while French and Webb were putting together the cockpit in their shop further up the coast of Maine. Having designed a smaller wooden vessel with the same ideal of traditional appearance, Phin knew exactly what he wanted, so he could have construction begin, leaving him to focus on other design areas.
First, exact measurements to define the form that the cockpit must fit into.	Second, construct a model of the space using plywood and 2-by-4s in the F&W shop.
Then, begin construction.
Halfway done. No sole or paint yet.
	Todd French and Peter Webb in their shop.
The cockpit structure was designed so that it would slip exactly into the hole in the deck. Once the boat had progressed so that there was less need for access to the space under the cockpit, we could use a crane to hoist it up, then use rollers to place it exactly.
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Lion's Whelp is tucked half under a huge "I" beam which is the crane's rails for the building. We had originally thought that we were going to have to move her out into the center of the bay. We hated the extra work.	We eventually saw that if we put the deck house and cockpit unit on the fore deck we could roll it under the" I" beam and get it back to where it belonged. Inches to spare, but an inch is as good as a mile!
The Deckhouse and cockpit has a truss strong back to keep it from bending. The rollers were pipes on the deck.	It is almost in place.
The cockpit in place, the strong back was removed, using our engine lift crane, we dropped the cockpit and deck house onto the boat.	It fits! Of course Peter knew it would all the time but I think I saw a sigh of relief.
	French and Webb also built the deck furniture. The main cabin scuttle and deck boxes about to take the ride up to the deck.
Once the cockpit was placed and secured, there were a few projects to consider. Here we see the cockpit table design being tested, then the installation of the mechanics around the helm. By far, you spend a great deal of time in and around the cockpit. Getting the layout of all of the equipment to be both functional and pleasing to the eye is a difficult task. Here we have Peter working on the gearshift mounted, similarly to Prowess, on the side of the wheel's worm gearbox.
The white column is the shape of the base of the binnacle. The table slips over the top and has another fold-out leg.	Joanna tries out the mocked up table to test for legroom and space enough for a full meal.
Establishing the relationship between the wheel, gear shift and binnacle mock up.	Gear shift cut into the wheel box side.
Peter fitting the gear shift to the wheel box mock up.	Finished helm station and binnacle.

Deck
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We begin with a completely open deck that allowed us to use a crane to lower heavy items such as the engine and generator. Covering the deck began on the edge of the deck with building up the bulworks.
Rich and Brian put on the base grub for the bulworks and covering boards.	A clean shot of the bulwark grub being glued on.
	Dave Smith fastens in a stanchion base.
Shows the stanchion bases and the stainless backing block.
The jig for drilling the bolt holes for the whisker stay tang.	Bulworks going on. Inside the bulworks there are two layers of 12 mm plywood sandwiched between two outside layers of 12 mm teak.
The multiple layers enclosing the deck.
The first level is installed. This is the cabin headliner, halfway up the deck beams.	Shows the insulation in the deck and the lights and wires run. Plastic squares keep the epoxy, which is on the back side of the deck, from sticking to the lights.
Mike Smith wiring the deck.	AC wiring coming through the headliner.
Another view of the installed insulation.
The top of the insulation layer was flush with the top of the deck beam, a layer of marine plywood goes on top.	Hammering the deck down.
There were a lot of nails.	Base for main cabin scuttle deck box top.
We asked Teak Decking Systems to construct the top layer. Here we see the teak deck arriving by truck in long sections.	Teak Decking built sections of the deck, some 53 feet long, and we put the together like a big puzzle. Here a segment is on sawhorses while epoxy is spread on deck.
Coating the deck with epoxy is both an adhesive and a waterproof layer.	Goo!
After this final layer, the bulworks were finished and they, along with the deck furniture were finished and varnished.
Two pictures facing forward as we see the crew working hard on the deck.
Varnishing the bulwarks takes a long time, but they sure do look good!
Mike places the 5th coat of varnish on the forward hatch.	A mockup of the spinnaker turning block.
Facing aft from the breast hook.

Here are a few pictures of various deck projects.
Foremast opening.	Ty rides the bowsprit while fitting it through the bulwarks.
Bow with area for windlass.	Epoxy deck insert under windlass.
Working out the details on the bowsprit base.
In the below 5 pictures, you can see the development of the breast hook. Starting with the template, multiple pieces of wood are scarfed together and sanded and varnished to a fantastic shine, through which will go the bow sprit.
The forward fife rail and dodger construction.
Close-up on Fife Rail.	Fife rail. Is the turning post the right dimension?
Templates for the dodger -- built and designed by Mobile Marine Canvas

Rigging:
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Mast Collars, Crantz Iron, Sampson Post, and Forestay Tang.	Fore mast step.
	Main mast step Shows engine box waste heat vent holes. The heat from the engine box is blown up the main mast to help defuse heat and warm the saloon. (No exhaust gasses.)
The bowsprit with mike in the background. Mike is varnishing the fiddles for the shelves in the main cabin	Hardware for the Bowsprit
End of main boom.	Main gooseneck not finished.
Peel back the wrapping on this extra-long carbon straw to reveal something amazing:	Only upon close inspection can you tell this is not wood!