The hardware is always a challenge . All of the hardware is custom
made , usually from sand castings . The left photo is the pattern for
the exhaust tips . The wooden pattern is used at the foundry to create
a hollow impression in sand the shape of the desired part . Molten
metal is poured into the cavity , and when the metal cools the sand is
broken away leaving the casting . Hollow castings like this one also
require a "core box " . The core box is used to make a block of sand (
a core ) with special indexing tabs that align the core inside the
cavity in the sand formed by the pattern to eventually form the hollow
inside of the finished part . It's a bit hard to explain , but the
exhaust tip on the right is the end result .
The windshield is made out of several castings , as well as extruded
channel silver brazed together for the frames. I assembled it on the
deck to check for fit before taking it apart and sending it out to the
plater . The hatch binder was also cut out of a sheet of brass and
fitted before plating . A lot of boats use strips that are butt joined
, but I prefer the look of a one piece binding with no joints .
A collection of rough castings ready for chrome .