Hull Repair

• [View 1] This is a shot from the aft starboard quarter. Damage to the hull is readily visible, as is that to the upperworks.
• [View 2] This the port bow.
• [View 3] The port stern is shown chewed up, and the aft mast is askew. Notice the 3 ripped holes, typical of an angled shot. This damage alone can kill a merchantman if at or below waterline. Some ripped / torn holes are stopped only because the penetrating round encounters a rib.
• [View 4] The same area as above, but at a different angle.

  ---

• [View 5] This is the port stern with the damaged areas cut away. The missing rectangular section used to have the rips. When that sort of damage is so densely packed, it is best to remove the plate and re-skin the area. Notice perfectly round holes forward of the re-skinning area. This is where round sections of skin were cut out with a "cookie-cutter". They will be filled with round plugs. Cookie-cutters are simply K&S brass tubing sanded to a sharp edge. These are rotated through the skin, with a hardwood backing block, which supports the material that will not be cut away.
• [View 6] When the patch and plugs are installed, they are sanded and filled to match the rest of the hull.

  ---

• [View 7] Starboard bow, with hits above, on and below waterline.
• [View 8] The same section with damage cut out....
• [View 9] ...and patches in place.

  ---

• [View 10]  The port bow. Here is another example of ripping holes. A 1/4" round can open up a 1/2" to 3/4" area hole.
• [View 11]  The nine holes here have been cleaned up with one big cut out and 2 circular holes.
• [View 12]  The patches in place. The skin used in replacement is the same thickness as that removed. It is bent and fared into the shape of the hull. Patches are generally made from on piece of wood.
• [View 13]  A good close-up of the repaired area showing the great workmanship of Mr. Dugan. See how the patch fits tight into the hole, even where the corners are rounded?

  ---

• [View 14]  The starboard stern. Truly an amazing example of the amount of damage a ship can receive. This portion of the series also shows how easily such carnage can be repaired.
• [View 15]  While this illustration of skin-removal seems extreme, it's really is not much more effort than the earlier patchwork. And it beats trying to patch every little and BIG hole. When skin is cut away, it is best to do so along the lines of ribs if possible. This provides for backup structure to support the back of the new patch. Otherwise, the patch will have to be butt-fitted to the old hull skin, a much weaker technique.

  ---

• [View 16]  The damage is repaired, and final finishing before painting can now be done. The large patch curves very nicely with the shape of the hull.
• [View 17]  Superstructure gets damaged too....
• [View 18]  Another view of superstructure repair.

  ---