Bar Harbor Wooden Boat
Spray: Stern Repair
The May 2009 survey indicated that the stern area of Spray was in the greatest need of repair, with rotten frames and floors and a badly fatigued horn timber.  The transom was working loose from the side planks, especially on the port side.  And the rudder could be moved from side to side because of the degradation of the horn timber. 

Starting in January 2010, disassembly began, starting with the dive platform and rub rails.  The aft bulwark and transom planks were removed, then the backing plywood for the transom.  Transom frames then came out, followed by the original iron fuel tanks (after emptying the diesel completely).  Bottom frames and floors were next to be removed, allowing access to the horn timber and underlying keelson, which itself was rotted.


New frames, floors, a spliced keelson, and horn timber were fabricated from white oak and primed with red lead.  White oak came primarily from Maine Coast Lumber in York, Maine. The 6-inch-thick piece from which the horn timber (and bollards) was cut came from New England Naval Timbers in Cornwall, Connecticut, and consisted of a section of trunk and major branch, giving especially strong grain (unlike the original, which was cut from a straight grain piece). 

New silicon bronze fasteners were obtained from Hamilton Marine, Southwest Harbor and Searsport, Maine.  The old Everdur fasteners seemed healthy enough to re-use, but a professional boat builder at the Maine Boatbuilders' Show said "they're not, replace 'em". 
Removing one of two fuel tanks with Come-Alongs -- a heavy job!
Stern of Spray after removal of transom, fuel tanks, floor timbers, bottom frames, and horn timber.
Old bottom frame and floor timber with their new, primed replacements
Cutting the new horn timber from white oak
The new horn timber, the fatigued old one, and part of the remaining white oak from which the new one was made.
Drawing from Rudder magazine, March 1963, showing Spray's construction details