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Restoration of the Masts and Fittings
wood arrived : masts : blocks and ironwork : mast lift-on
April to May 2003: The spars were almost complete and the wood for the masts had been ordered. Work continued to replace worn components on the engine and a deck wash had been installed. More lead ballast had been cast and laid on board.
The wood for the two masts arrived and the lamination started straight away under the direction of Keith Billington who had experience of wood lamination with work carried out for the National Trust.
The wood was marked out and assembled for laminating prior to the formation of the main and mizzen masts.
June to July 2003: The main and mizzen masts were glued and clamped for lamination and then shaped. Douglas Fir "clear and better" timber was used and 80 odd clamps were fabricated for the job.
The foremast is shown finished - note the squared heel which rests in the trunk and is chocked in the sides of the carlings of the scottle. The heel of the foremast originally was rounded to facilitate lowering when it rested on the mast thwart. The scottle was slewed slightly to port so the mast head could lie between the mizzen mast and its backstay. The mast is now ready for the ironwork with a slot cut out for the iron capping.
The blocks and ironwork are seen assembled at K.A.B. Metal Work at Rospeath Industrial Estate in Crowlas where all the work on the Happy Return had been carried out. Keith Billington who owns the works and has provided so much of his expertise and time is seen examining some of the work with another of the association members.
August 2003: The masts are stepped early in the morning on the 8th of August 2003 by crane on the Albert Pier in Penzance after being loaded down from Crowlas. The foremast is stepped in a mast case or tabernacle inside a long narrow slot in the deck known as the scottle. Note the wedges or "chocks" around the mast. Originally the scottle had grooves cut in the sides into which a strong chock was dropped to stop the mast coming aft. When the mast was upright the scottle was covered by a hatch or covering board, but since the foremast won't be lowered aft in this case, a fore hatch was fabricated in it's place although the scottle was often originally used to access the peak.
There is also an illustration of a traveller (called a "parrel" at Newlyn) used by this type of lugger