

| Building Falcon |
| Research and education added about a hundred, maybe two hundred, books to my already insensibly large library. I spent the majority of my spare time learning and designing, sketching and shopping, and of course, wandering through the forests of masts in coastal New England boatyards and marinas. I finally found a place in North Kingstown, Rhode Island, where a man was collecting old molds and selling hulls. The hull I went down to investigate is actually the one in the background of this picture. It is a 47' full keel offshore sloop design with a pretty forward underbody and a disturbingly ugly aft underbody. The owner also wanted way too much money for it. |
| One of the 'old sayings' I'd discovered at this point focused on what the old-timers referred to as 'blow of the eye'. "If you see a hull and it looks wrong to you, it probably is. You do not need to be an accomplished sailor or a naval architect." The old pastime of wandering through winter boatyards and looking around while waiting for spring pays dividends. Most of the boats stored there are good boats with good hulls, and you get used to it. After crunching all the numbers again, I knew my finances could not support the 47 footer, and opted for a hull out of the mold in the foreground of the picture. It was described as a "32 and a half foot replica of Slocum's 'Spray', with a 12 and a half foot beam and 5 foot draft. The mold was built by one 'Hans Otto Horne', somewhere in Florida and sometime around 1953." I just got a hull and designed my own version of a schooner. This is the hull where it was stored after Hale Pauley screwed it up. I didn't see any good in complaining about being taken and just made the best of it. |
| Something that sadly escaped my attention during my initial inspection of the hull, but can be seen clearly in the stern view above, is that the right side of the hull is thinner than the left side. A few measurements later and I confirmed the truth: Pauley had laid up two more schedules of 24ounce woven roving and 1 1/2 ounce coarse strand mat on the left side than the right side. Brilliant. I don't know if it's booze, years of drug abuse, or just being high as a kite on the fumes of curing polyester resin, but the bozo screwed the pooch and left me with a big fix before I could even start building a boat. But, even before that, I glanced at the cloudy sky and felt the approach of autumn in the air. The location I'd been lucky enough to arrange was about 20 feet from the waters edge on the northern tip of Lynn Harbor in Massachusetts. A lifetime on the New England Coast brought me a healthy respect for the weather that was certainly on the way and I had to build some kind of suitable shed to allow working through the winter. As briefly as possible, I met a man named Nebelkopf who was involved with condominium development on the location, and he offered me the spot and whatever water and electric resources I might require in exchange for my help (at a reasonable rate) in the complete, frame-off restoration of a 1959 Cadillac El Dorado Biarritz. There was also an abandoned building on the property (barely visible behind the tree in the stern shot of Falcon's hull) that was scheduled for demolition. The building was a metal structure of 50 feet by 100 feet with a second floor made entirely of wood. He offered me the wood if I could remove it. Done. After a huge amount of effort. |
| It turns out that part of the support for the floor comprised of 120 Douglas Fir beams that measured 2 1/2 inches by 7 1/2 inches by 22 feet long. It's like the best Christmas stocking present ever! I couldn't believe it. Without saying anything, I worked like a dog disassembling the entire loft and carefully stacking and grading the lumber, pulling a full 55 gallon drum of nails out of it as I did. I carefully hid the very best of the big beams in the middle of the pile, knowing the owner would suddenly see the value of the huge piles of long beams and being sorry for the deal he'd made, want something more. Luckily, there were also about 100 22 foot 2 by 8's and forty or so sheets of 3/4 inch plywood, none of which I had much interest in, so when the vultures swooped in to scavenge, I defended the cache like a rabid Hun and out of the kindness of my heart and generosity of my glowing soul, allowed them most of the 2 by 8's and all the plywood. That way I didn't have to carry the crap around any more. I kept about half of the 2 by 8's to make the trusses and scaffolding for the shed, all the 3 by 8 beams and all the 1 inch pine flooring. |
| With the useless lumber disappearing over the horizon along with the cackles of the takers, I separated the rest of the lumber into two piles: one for the boat (all the very best of the wood) and the rest for the shed. They even left behind some of the damaged plywood, which you can see at the rear of the shed. I sent away for and received a large, tough tarp (you might also include 'heavy' in that description) that was white on one side to reflect the summer sun and help keep the shed a bit cooler, and black on the |
| other side to help warm the shed. I also wired in some old 8 foot fluorescent lights, and this picture is the first tryout of the lights with the tarp in place. The white inside also made it brighter. |
| Officially, winter was here. It just hadn't snowed yet. A large pile of lobster pots can be seen directly behind the shed where they are stored. Don't believe a word about lobster pots stinking like the bottom of the ocean at low tide. You can hardly smell them at all once they're frozen. If you breath through your mouth. I worked 16 and 18 hours a day closing in the shed with heavy, clear plastic, stapled on with canvas strips and wood battens to survive the winter winds. I also lashed down the heavy tarp as though a hurricane were coming. I'm intimately familiar with New England winters. It held, and more, it warmed up the shed inside. It became quite comfortable in there and made working fairly pleasant. I also worked on building a scaffolding around the hull, and closing in the back end of the shed with wood and plastic and the front with a set of doors 12 feet high and 8 feet wide. I also built two small doors for easy access. It snowed just days after I finished closing it in. |
| I've always liked this picture. A hundred little cans of auto touch-up paint were gathered up and placed on a makeshift table to see if there was anything of any use before they were all tossed. A half dozen or so friends and I talked and passed the time opening them and slobbering the colors in a stripe across the doors, for no reason other than to see the colors. Later on that day, after everyone had left, I cut a silhouette out of some thin plywood, painted it black and tacked it to the door. It stayed there for two years while I built Falcon. I also got kind of a kick out of the arched window over the doors. That was some kind of a desperate compromise to join the shed roof to the door frame in as reasonable a way as possible. I built the doors and frame together on the ground as one large assembly and stood it up one night in a desperate and ridiculous affair that almost left me pinned on the ground beneath them. As I nailed and screwed the frames, doors and hinges together on the ground, right in front of the opening, it got heavier and heavier and I began to wonder how I could stand the assembly up and get it in place. I brought a barrel over and lifted one corner and kicked the barrel under, then the other corner. I put a five foot 2 by 8 in the middle and shouldered the assembly higher, propping the 2 by 8 under it. I put an 8 foot 2 by 8 under it and slowly worked it up higher and higher, until the entire assembly was propped at a 45 degree angle with an 8 foot 2 by 8 holding it up. I wondered how heavy it was, and if I might possibly be able to just push it the rest of the way up, so I got underneath, in the middle of the doors, put my hands straight up over my head and tested the weight. The 8 foot 2 by 8 came loose and fell, bonking me square on the back of the head, then falling to the ground. I was so surprised that my knees buckled and I thought I would collapse with the whole weight of the doors and frame on top of me. It was very cold and late at night and I heaved against the weight, pushing the doors up and slipping my hands lower. In about 20 seconds, the doors were upright and I pulled one of them open to stabilize the assembly. I had to do it because I would have been SO ashamed to die like that. Good grief. My back hurt. And my head. |











| There is a condition of the mind that those who possess it know and those who don't will never comprehend. It is an efficiency of mental resources that allows you to carry on tedious tasks like an automaton, without applying a higher level of concentration, which is instead busily working out future difficulties. People like to call it 'multi-tasking', but those who use the phrase most frequently are those least likely to understand the concept. Consequently, I never use the term. While stapling on all the plastic, I was working out the big doors. While fastening the doors, I designed the small doors. While sorting the lumber, I struggled with how to satisfactorily make and install a pair of brutally tough sheer clamps. This picture shows the final result. I found the two clearest, straightest, and heaviest beams in the stack, and from them cut four |

| beams which I finished to 2 inches by 2 1/2 inches by 22 feet. Next, I cut and epoxied a 26 inch scarf in each and joined the pairs into two sheer clamps that were almost 40 feet long. The beams were heavy and unwieldy, so I suspended the first one from the shed trusses and tried to force it into position in the hull. No go - not a chance. Next, I secured block and tackle to the ends of the suspended beam and began to curve it like an archers bow. The minor groaning of the wood didn't frighten me, but the explosive failure of the scarf, followed by me and everything else crashing down into the bilge scared the hell out me. You know - for a second. I got over it. An inspection of the scarf revealed no damage, simply that the feathered end of the scarf began to lift and the joint itself inevitably peeled apart. I redid that scarf and put it aside to cure while I started again with the other beam. This time, prior to bending it, I wrapped the feathered tips of the scarf joint with some tightly drawn .020 stainless steel safety wire. The beam bent perfectly and the joint held without a problem. Next, some epoxy and every clamp I owned held the sheer clamp in position while I bolted it every 8 inches with 5/16 stainless steel flathead screws, washers and nuts. It brought a new stiffness to the hull that I liked. The bolts securing the sheer clamp were countersunk both on the outside of the hull as well as on the inside. You can just see them in the picture above. At this point I burned up three perfectly good, though old and dated, circular saws as I trimmed the entire length of the 3/4 inch thick fiberglass hull down to the newly installed sheer clamps. The saws filled with fiberglass and resin dust and actually caught fire in my hands. Still, they made it through the job. I, on the other hand, still shudder when I think of how coated with fiberglass and how itchy I was for days. The next project was the shaping and installation of the main beams. Everything was notched into each other, epoxied and bolted. Many of the trickier beams were laminated up in place and secured or positioned using some methods I had to come up with on the spot. Certain dimensions were the product of long design and study, or investigation of the hull itself. For instance, the position of the athwartships beams at the forward and aft ends of the cabin were a product of design specs. I knew where the cabin roof should start and end. The aft end of the cockpit was more or less forced by the position of the rudder and the angle of the keel. The sides of the cabin and width of the side decks were more complex, however, and I first had to determine the floating level of the boat and adjust the blocking with a hydraulic jack and pyramid level (clear hose with water in it) and scribe a waterline. From there I used a plumb bob and level inside to outline the cabin sole, and from there determined the deckhouse size so I would have standing headroom wherever there was floor. Once I had the right layout, I laminated in the cabin side beams. |



| Even though the second picture was first, I like they way they look in this order. I installed four 5/16 stainless threaded rods on each side, countersunk into the hull on the outside and clamped with washers and nuts on the inside. They also had washers and nuts on both sides of the cabin side beam to perfectly locate the beam during the fabrication and installation of the short deck beams. Each of these beams is notched into the cabin beam and sheer clamp with a tapered end, epoxied and bolted with 5/16 SS bolts, countersunk to facilitate deck planking. Also notice the heavy triangular gussets between the main deck beams and the sheer clamps. Those are also epoxied and bolted. This boat is strong. |






| Frankly, there were times when I was having so much fun and making such good progress, that I just didn't stop to take many pictures, even though I usually worked 14 to 18 hours a day on the boat. Of course, I also took time away to earn money, but not nearly as much as you might think. The first winter, however, was fairly dominated by the restoration of the Cadillac. You know what? I'm going to stick the Caddy section in right here. It isn't that big a deal and I sure don't need to dedicate a whole section to it. The picture to the left was taken sometime during the second summer, the first being when I was salvaging the wood. By this time, the plastic on the shed had sun-rotted and was all torn away, making for a great summer shed. A short time later, as in the shots below, new plastic was installed and a hole was cut through the big doors to allow the bowsprit to stick through. |
| All the framework was smoothed and coated with epoxy, and as you can see in the second picture, I used the same method with the SS threaded rod to locate the cockpit side beams, which were also laminated in place. There is a degree of this that is purely artistic in determining arches and curvatures, spacing and dimension, but once again, if something is structurally unsound, you'll see it. I've always liked the way the finished deck framing looked, and after 20 years, still have no reason to doubt it's strength and integrity. |
| Okay, then, lead, lead, lead. The hull was originally designed by Horne to have 5500 pounds of boiler punchings and concrete, or some other such unlikely substance deposited in the bilge. Of course, he also designed the masts to be chopped down in the nearest City Park, and the rig to be a ketch. And worst of all, he designed the deck to be recessed about a foot below the sheer. Great googely moogely. I wasn't up for any of that. I wanted 8600 pounds of lead for a 43% ballast ratio, and I got it. Lead was hard to find in any serious quantity and at the time it was between $1 and $2 per pound, supplied in 50 or 60 pound ingots. |
| Averaging, I had to guess at about $13,000 to buy enough lead for ballast. Ouch. I started picking up loose wheel weights along the roadside as I walked around town. Then I started buying buckets of old wheel weights at the tire stores for 15 cents a pound. A friend with a lead washer business began selling me his scrap, lead sheeting with a million little holes punched in it, and millions of tiny lead discs punched from the center of the washers, also for 15 cents a pound. A guy at a boatyard told me there was a 2500 pound lead keel from a sunk boat that they'd load onto a trailer for me for $500. Done. Now we're getting somewhere. The last stop was a boatyard in Marblehead that had a 5500 pound lead keel lying in the bottom of the haulout slip. Apparently, it had torn out of the bottom of an old boat during haulout, and been there ever since. Once I squared it with the old boat owner, the yard picked it up and put it on my rented trailer for a measly $200. Now, all I had to do was get it back to Lynn and off the trailer. The trailer was a U-Haul and rated at 2500 pounds, so when the 5500 pound keel was set on it, it squatted to the rubber bumpers and almost disintegrated them. The axles bent and the tires squashed and everybody but me laughed. I still had 20 miles to go. Fortunately, I'd had the foresight to lay a dozen 2 inch pipes in the bottom of the trailer to help with rolling it out. With my teeth clenched and my eyebrows arched til it hurt, I eased the groaning load to the boat in Lynn, where a bunch of people gathered and wondered how in all that is sane and rational, was I going to get that thing off the trailer? No problem. I told them to stand back and I got a lever and tried to roll it on the pipes. No deal. Not a chance. Okay then, I put a jack under the trailer tongue and released the car and parked it, leaving the trailer alone in the middle of the yard, right in front of the big shed doors. Then I began jacking up the tongue, the idea being to make it easier to roll out. The higher it got, the scarier it got. People laughed nervously and stepped cautiously backward as I went back and forth. All of a sudden it moved. I jumped back and the lead rolled out of the trailer and the trailer shot across the yard like a pinched watermelon seed and the damn ground shook when that keel slammed down. Easy as pie. The keel now lay as if it were nailed to the center of the Earth. It took me two full months to cut into manageable sized lumps. |
| I built a wooden dam to keep the lead from flowing aft into the rear bilge, then began laying lumps of lead into the bottom of the keel as I melted pot after pot of lead, scraped off the impurities, and poured it carefully onto the lumps, melting it all together into one large block. I found I could melt five pots of about 40 pounds each, per hour. I also had to keep bringing more and more lumps from outside into the boat. I did the entire job in one 46 hour session, and when it was over, I'd melted 7100 pounds of lead into the keel. It took a week to cool. When it did, it shrank a tad and I poured a gallon of tropical mixed West epoxy around it, which oozed in around it and cured, then I fiberglassed it into the bilge. |
| Something about the keel trunk that I haven't mentioned is the fiberglassing I did around it during the big project to thicken up the starboard side. Somehow, somewhere, I seem to have lost the pictures I took of that particular job. I know I had them, but, yeah, well, you know. It occurred to me that the entire lead keel casting COULD possibly tear loose from the keel trunk and plunge straight through the cabin top, IF Falcon got pitchpoled by a big wave and slammed down on the water upside down. This scenario is spooky enough without the keel lead launching itself into the great black at the bottom of the ocean, leaving a giant hole in what would now be the bottom of the boat. Not to mention that the boat would now have no reason to roll back upright. So there I was, already all sticky with resin and fuzzy with a million glass filaments halfway to my elbows as I finished the side work (probably a little high from fumes as well). I ground a proper prep into the surface around the top of the keel, a foot up into the bilge and a foot down into the keel trunk, then laid up a full half inch of thickness on each side, creating a one inch bottleneck at the top of the keel trunk. The added material also brought the hull thickness in that area to a full 2 inches. Falcon's hull is built like a tank. Yeah, I know - heavy - but blah blah blah - I don't intend to run around, but a thousand things have happened that I never intended, and I'm sure grounding will soon make the list. There were very few pictures taken of me during this whole boat building thing, but I do have one and I've decided to include it. I hope it doesn't seem vain, though I doubt many will think so since I look like a homeless vagrant, but It does give a picture of who is doing all the talking here. |
| By this time I was finishing up all the main framing, laminating in the forward cabin arch beam and the aft cockpit arch beam, and preparing to melt in the lead. "What happened to all the time?" you might ask. Well, it's like this - - - lead. Sailboats have keels and keels are made of lead and lead is difficult to get at best and very expensive at worst. Not only that, it's a tad tough to move around and work with. More on that in a minute. |

| I'm older now with less hair, but I still own the shirt. No, that's not true. I tossed it a month or so ago. That's what happens when you store things in sailbags by accident. The beams selected for the main floor stringers and braces were all clear and hard. I had to use some old boat builders tricks from old books to shape them so they fit perfectly, then I epoxied and fiberglassed everything to the hull and each other. Again the shed was filled with the smell of fresh sawdust instead of polyester resin. Gratefully, the West System epoxy I used for most of the work had little or no odor. If it did, I couldn't smell it. I don't smoke anymore, but at the time I did and might not have had the best nose for those things. |


| All the floor timbers were aligned to be perfectly level from fore and aft as well as side to side. Naturally, I constantly rechecked the level of the hull itself many times during construction, or a tool like a level is worse than useless - it becomes an enemy tilting everything to one side. After adding 7100 pounds of lead to the hull, I had to be sure it hadn't crushed any of the blocking into the ground or pressed a stand away from center. |

| Fitting and installing the engine beds is another critical job that required a large number of things be underway at once. For one thing, I had to have the engine I'd be using, as well as the gearbox, motor mounts, prop shaft, and the cutlass bearing fitting. The only way to be really sure the engine beds were in exactly the right position and at the right height, was to have the engine and shaft in the boat. Everything hinges off the shaft. Falcon's hull left no options as to it's position, so I started there. It had just one spot and it had to be level. I already had the engine by now, but left that section to be added after this one for no particular reason. Anyway, after assembling the engine and setting the motor mounts to the middle position, I took all the necessary measurements to make the mockup above. I bored a 1 1/4 inch hole in the center piece to accept the shaft at the correct height and attached the flat panel to the new engine beds with screws dead center where the engine mounts would be. From there, fitting the |
| engine beds to the complex curves of the hull and bilge were easy. When it was right, I epoxied and glassed the beds in place. |
| 1959 Cadillac El Dorado Biarritz Convertible |








| In truth, this is not my kind of car. Still, I must admit I had a fairly good time doing the restoration. Everything, and I mean EVERYTHING, was stripped off, cleaned,properly reconditioned or replaced with an appropriate alternate. Restoration aficionados are extremely finicky about what constitutes an acceptable replacement part in a true restoration project, as well as what materials are used and exactly how each job is to be done. Many a hopeful restorer has actually totalled the vehicle by doing it wrong. The man cleaning the engine, Cary Nebelkopf, became obsessed with this attention to detail and strict adherence to the rules in every respect. At least he wasn't a fussbudget or cheap. It cost $10,000 to get the right skins, have them dyed exactly the correct shade, and have the seats and door panels properly reupholstered by a select professional who does this kind of work for a living. Everything said and done, it was worth it. Every bit of it was worth it. |
| Nebelkopf put $100,000 into this project. There were times when the money was spent over and over for the same component, such as the taillight assemblies, because the ones he kept getting were simply not good enough. When I gently quizzed him on his mental health, he just grinned and said, "Someone will buy them from me." Meaning the extras, of course. |
| I couldn't be happier when this project was finally done, because I just wanted to work on the boat, but it wasn't too long after the car was finished that Nebelkopf told me I had to get off the property. The original deal of "you finish my car and I'll let you stay until you finish the boat," vaporized almost as soon as the car was done. For me, it did not come as a surprise. I wrote some things here that were thoughts straight off the top of my head, but an email from an old friend convinced me to look again and I found the statements to be mean spirited and unneeded, so I have removed them. Cary threw me out and I saw it coming. Leave it at that. We haven't spoken since. |
| When the car was done, there was time to make it to the very last show of the season. It turned out to be a beautiful fall day and the Caddy took first place overall, best in show or whatever. I forget, to tell the truth. Somebody offered Cary $175,000 for the car and he turned it down, quite honestly, as I thought he should, feeling the car would draw more money soon. I was wrong. We were all wrong. It wasn't long before more versions of the car were on the market and the prices fell. The last I knew, Cary was using it as a daily driver. It is a great car. Another guy who did considerable work on the car was Dave Bourbeau, who wrote me the email. He lives in Florida now and I'll have to ask him what ever happened to his restored 43' Egg Harbor Sport Fisher. Updated February 9, 2009: I received a site Contact email from Cary yesterday thanking me for toning down the angry remarks, and making a good job of taking the sting out of the old injury. Perhaps I never should have written them at all, but as a result, I no longer feel any hostility toward him and feel a bit foolish for having been so immature to include the comments in the first place. Anyway, after 20 years, an important bit of healing has taken place and I'm glad for it. |

| Back To Falcon |
| I have decided to make estimates of the approximate years that these activities took place. They are only guesses, however, but should be fairly accurate. 1986 |
| 1987 |
| This just in: Sunday, March 29, 2009 - Bill Refakis, creator of the 59 Biarritz Survivor Roster on the Cadillac & LaSalle Club, made contact with me and informed me that, "I research these 59 Biarritz survivors, and purchased from Cary a 62 and 64 caddy to help finance his project, for all his insanity, the car ended up owned by the owner of the Coney Island, Brooklyn waterfront and was stored in a waterfront shed for 10 years, and ended up quite rusty and crusty!" That's kind of a shame, because the car WAS nice and there was certainly a lot of money poured into it. Too bad. |







| I may never remember where I heard about the Pathfinder Marine Engine, But I'll never forget that the price was right. For $2000 I bought a good used Volkswagen diesel engine and all the conversion components to make it a Pathfinder. It's a great engine. Volkswagen made millions of these engines, ranging in horsepower from 48 to somewhere near 100. As far as I know, they are all able to be converted to a smooth and powerful, as well as fuel efficient, marine engine. I started with a 48 horsepower unit but have since moved up to a 52 horsepower model. The stronger engine is really MUCH stronger because it produces about 50% more torque over the entire RPM band. One of the best features of the Volkswagen engine is that it was designed for smooth and quiet automotive service, and sounds nothing like the pure industrial diesel boat engines that sound like they're trying to throw a rod every time you start them. So far, there is no evidence that the 'rock crusher' sound effects of the other engines offers them better service or longer life. Besides, you can get a fine replacement for the Pathfinder core at any salvage yard for under $300. |
| After stripping it down and scrubbing and solvent washing every last nook and cranny, the block and every part were carefully taped and painted. I also located the Pathfinder people and got drawings and specs, bought a new Volkswagen Service manual, and compiled a significant stack of documentation. Too bad I didn't get it before I over-torqued an injector and cracked the cylinder head. The engines one weak spot - aluminum cylinder head. I patched it up and it held, but I knew I'd be replacing it soon. |
| All painted and assembled, with nothing yet to do but install the injectors and crack the cylinder head. After more than twenty years, I still like these strong little engines. They are compact, powerful, and the smoothest little marine engines I've ever found. |
| This is the instrument panel I made out of miscellaneous instruments that never worked and a piece of scrap Plexiglas. Well, the ammeter and the engine hours thing worked. It was a sort of 'make believe' panel that fooled others into thinking I had the whole package. I think someone might have been fooled. It made me feel better to make the effort, but the result was disappointing. Here we go again into something totally different, requiring more tools, more skills, and unique injuries. All during this project, people brought me supplies I couldn't turn down. One such item was a 14 foot bar of 2 inch stainless steel |

| round stock. Another was a long solid round of one inch stainless. These formed the basis for Falcon's rudder, I was sure, but had no idea what to do or how to do it until it was time to do it. I measured the boat with the deck framing and cut the 2 inch stock down to 9 feet, then secured it to a scrap piece of plywood and drew out the rudder's shape. I wandered through the dump that the lot I was working in had become until I found and abandoned trailer with an appropriate sized hole in part of its frame. I inserted the 1 inch round stock and climbed it, bouncing a little until it bent slightly, then went back to my little rudder drawing jig and tried it out. A little at a time, the 1 inch bar curled into the shape you see here. I cut the excess off the bottom end and used it to form the diagonal brace at the bottom. The last bracing I did was some 1/2 inch square stainless bar stock I bought at a salvage yard. |
| I bought welding rod, borrowed a welder, and commenced to weld. My Uncle Angel taught me the basics of welding when I lived on his farm through many summers. Uncle Angel taught me most of the things that are important. My father was not much into liking me. When I had the frame completely welded, a friend I'd recently met dropped by to see the boat and when he looked down at the rudder assembly, he asked, "Who the hell welded this?" I might have had a fleeting thought about blaming it on a pack of drive-by |
| 1988 |