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HISTORICAL DOCUMENTATION

Patrick Otton, Technical Writer
Naval Historical Center Detachment Boston
Bldg 24 M&R B.N.H.P.
Charlestown Navy Yard
Boston, MA 02129 USA
617-242-0752, phone
617-241-5232, fax
e-mail: potton-nhcdetbos@worldnet.att.net

Naval Historical Center, Detachment Boston logo

HISTORICAL DOCUMENTATION

TITLE: LOWER MAST CAPS; Inspect and Refurbish
CONTROL: D-92-0009
D-92-0009.1
2K: 01024 340 0009
D-92-0009
Job Duration:
START: 10-1992 COMPLETION: 11-1992

Cost Summary:
estimate actual
man-days 10 8.5
material $ $


D-92-0009.1
Job Duration:
START: 9-16-1994 COMPLETION: 3-23-1995

Cost Summary:
estimate actual
man-days 95 56
material $14,000.00 $7,900.00


Approval(s):
964 1,2,3 or 972 ____________manufacturing
802 ____________materials and costs
900 ____________review
800 ____________review
100 ____________final

REFERENCES:
(A) BOSTON NAVY YARD DWG, 14947
US FRIGATE CONSTITUTION
MAST CAPS, dated: 1929


ENCLOSURES:
(1) MAINTENANCE HISTORY 3 pages
(2) 2 KILO, 01024 340 0009 1 page
(3) CONSTITUTION MAINTENANCE AND REPAIR DIVISION, 
Preliminary Materials Worksheet.
4 pages
(4) REQUISITION AND INVOICE/SHIPPING DOCUMENT 1149, N6893892RQ90501 
Laminated White Oak
1 page
(5) MATERIAL INSPECTION and RECEIVING REPORT 
Laminated White Oak
2 pages
(6) REQUISITION AND INVOICE/SHIPPING DOCUMENT 1149, N6893892RQ90103, 
Eye Bolts
2 pages
(7) REQUISITION AND INVOICE/SHIPPING DOCUMENT 1149, N6893892RQ90583, 
Galvanized Washers
1 page
(8) Fabrication Sketch 
Cap Band(s)
2 pages
(9) MANUFACTURING REPORT 2 pages
(10) CONDITION REPORT 3 pages
(11) PHOTOGRAPHS 14 pages 
29 Photographs

TABLE OF CONTENTS
BACKGROUND
2-KILO
WORK ITEM
MATERIAL ORDERING DOCUMENTATION
MANUFACTURING
TAG ISSUE
MATERIAL DISPOSITION
CONDITION REPORT
PHOTOGRAPHS

BACKGROUND

QUANTITY:
LOWER MAST CAPS, Three (3) total, one (1) each per mast.

DATE LAST REPLACED: See enclosure (1).

CONFIGURATION:

The masts of Constitution are made up of multiple mast sections; main. topmast, t'gallant/royal. Mast caps are used to join the sections together. At the top of the lower mast and at the base of the upper mast, the mast sections overlap, called the "doublings". Mast caps form a structural tie band joining the upper mast to the top of a lower mast at the doublings. The lower mast caps join the foot of the topmast to the head of the lower mast, for each of the three masts, fore, main and mizzen. Mast caps are so called because they sit on and are mortised into the top of the lower mast to give support to the mast section above it. Mast caps are necessarily large structural pieces to take the loads of the masts.

The mast caps have a mortise or square hole in the aft section for the lower mast head tennon and a through round hole forward for the upper mast to pass through.

The square tenon cut on the head of the lower mast orientates the cap into a position parallel with the centerline of the ship that ensures the proper alignment of the topmast. The dimensions of the caps assures that the topmast is held at a specific constant distance forward of the lower mast locking the topmast into vertical alignment with the lower mast.

The majority of the cap projects forward of the tenon. The round hole that is cut into the forward end of each cap to receive the topmast projects over the forward side of the fighting top through which the topmast will be stepped.

The tenon cut on the head of the mast is at an angle to allow the mast cap to attain a more level plane, rather then lay aft perpendicular to the centerline of the mast.

The round hole is generally leathered within. The square mortise hole is also leathered and in addition a copper sheet is placed across the upper surface to prevent the weather from getting into the lower mast head.

The corners of the cap are slightly rounded and a metal band, running around the perimeter is fitted on the upper and lower edges. The extreme edges of the bands are flush with the upper and lower edges of the cap. Integral to the mast cap bands are various eyebolts on each side, used as points of attachment for blocks used in the rigging.

The cap bands are four inches in width. There is a roller bolted through the after side of the top band and cap. The 5/8" bolts for the roller terminate and are clenched over in the aft side of the tenon hole cut to receive the head of the topmast. The roller is a fair lead for the main topgallant mast stays.

On all three lower caps, there is a metal strap that runs athwartship between the tenon hole and the topmast hole. This band turns down at a 90 degree angle, for approximately four inches at the sides of the cap and terminates on both sides with a 1 3/4" eye. These eyes are the connection points for the lower yard lifts. These athwartship metal straps are approximately 3 1/2" wide and 3/8" thick.

Not shown on the print but configured on the cap are oak chaffing pieces or pads upon which the yard slings bear. The lower yards are hung on yard slings. These slings pass from the lower yards up onto the lower caps and pass behind the topmast. The slings are in two pieces, and rest in a piece of dished oak that is secured to the cap. The oak is the same length as the cap lying in an athwartship direction.

Two additional eyebolts were found in the existing caps, located outboard of the tenon hole for the lower mast. These bolts are not on the cap plan, but were installed as new eyebolts in the location they were found in the old caps.

Lower Foremast Cap:
The cap is 6'-4" long, by 3'-2" wide, and 16 1/2" thick. The weight of the cap was #1500 lb.

Lower Main Mast Cap:
Cap is a rectangular piece of laminated oak that was 7'-0" long, 3'-6" wide and 18 1/2" thick. The new cap weighed #2025 lb. when installed.

Lower Mizzen Cap:
This is the smallest lower mast cap and measures 4'-11" long, 2'-5" wide and is 12 1/2" thick. The new lower mast cap weighed #800 lb. when installed.

The mizzen cap does not have an after roller. It does have an eyebolt on the centerline aft, that clenches inside the lower mast tenon hole. The spanker gaff peak halyard block secures to this eyebolt


CONDITION: LOWER CAPS, FORE, MAIN, MIZZEN

All lower caps have substantially large areas of rot that are not repairable. A second work item D-92-0009.1 was written to manufacture new lower mast caps for each the fore, main and mizzen masts.

There were concerns regarding the condition of the eyebolts and other metal hardware used on the upper and lower mast caps.

HISTORY

All three lower mast caps were manufactured from solid teak during the 1927/1931 Restoration. During the 1992 Repair all three lower mast caps received the same repairs and replacement as was accomplished on the lower foremast cap, detailed below:

Lower Foremast Cap:
The cap was removed and repaired in 1951, 1965, 1974 and repainted in place in November of 1983. This cap removed in 1992 was manufactured from teak.

A new laminated white oak lower foremast cap was manufactured and installed during the 1992 Repair. The weight of the new cap is #1600 lb. The laminates were glued to conform to the square dimensions of this cap. The old cap is being used for a new cathead.

The perimeter bands were removed, along with the roller stay, and were sandblasted and galvanized. The metal strap for the yard lifts received the same treatment. All six eyebolts, and the two bolts holding the stay roller were replaced with new galvanized fasteners. The chaffing piece in which the yard sling rests, and all of the wood associated with the cap was replaced.


Lower Mainmast Cap:
The lower main mast cap removed weighed #2,000 lb. This cap was constructed in 1953/1954, and repaired in 1973 / 1974. In the 1978/1979 period, it was again removed and repaired in conjunction with the repairs accomplished to the lower main mast tenon.

Lower Mizzen Cap:
The old mizzen mast cap weighed #1200 pounds. The new laminated oak cap weighed #800 pounds. The cap that was removed at this availability was manufactured in 1955. It was removed and refurbished in 1974, and painted in place in November of 1984.

PLEASE REFER TO RIGGING DOCUMENTATION FILES FOR COMPLETE DESCRIPTION

2-KILO

See enclosure (2).

WORK ITEM

All Work Item addendum(s) and change(s) follow.

DIFFERENCES/CHANGES between 2K and Work Item:

The original 2-Kilo was written to remove, refurbish, reinstall the lower mast caps during the restoration. The Work Item, IX-21-A-009 ADDENDUM ONE, required the removal, material condition evaluation, refurbishment, and reinstallation of the mast caps. A minor change, to have the inspection include 'signs of corrosion' was added in Work Item, IX-21-A-009 ADDENDUM THREE.

Upon inspection the fore, main, and mizzen lower caps were found to be severely decayed and beyond repair. A Work Item Change IX-21-A-009 CHANGE ONE (IX-21-A-009.1) was written to manufacture new lower mast caps. Work Item IA-21-A-009 Change ONE, required the new fabrication of all three lower mast caps and the reinstallation as part of the work item.

Work Item IX-21-A-009 Change TWO, modified the work item, to comprise of the refurbishment of the mast caps only.

The removal and installation of the lower mast caps is accomplished in Work Item IX-21-A-034A.

The manufacture of the lower mast caps is done in Work Item IX-21-A-009 Change TWO (IX-21-A-009.1), which is the execution work item.

Related Work:
See the rigging documentation files.

SHIP: USS CONSTITUTION IX-21 ITEM NO. IX-21-A-009
ADDENDUM NO. ONE

COAR: PCN: C340-0009 SURVEYOR: CONCANNON

1. SCOPE:
1.1 Title: Lower Mast Caps; inspect and refurbish

1.2 Location of Work: Fore, Main and Mizzen Masts

1.3 Identification: Qty (3) Mast Caps


2. REFERENCES:
a. Boston Dwg. 14947, Caps for Masts

3. REQUIREMENTS:
3.1 Remove the mast caps listed in 1.3.

3.2 Inspect the mast caps for signs of decay. 3.3 Accomplish test bores of the mast caps using a 3/8 or 1/2 inch auger bit drilled to the center of the piece being tested using 2.a. for guidance.

3.4 Submit a report of the conditions found to the Constitution (M & R) Division.

3.5 Upon completion of each test bore, glue and plug each test bore hole with the same species of lumber.

3.6 Refurbish the mast caps.

3.7 Preserve, prime and paint the mast caps prior to installation.

3.8 Install the mast caps using new fasteners.

3.9 The new fasteners shall be Galvanized Steel.


4. NOTES:
4.1 The mast caps shall be removed prior to drydocking the ship.

5. GOVERNMENT FURNISHED MATERIAL (GFM)
5.1 Material required for accomplishment of this Work Item shall be procured by the Constitution (M & R) Division.

SHIP: USS CONSTITUTION IX-21 ITEM NO. IX-21-A-009
ADDENDUM NO. THREE

COAR: PCN: C340-0009 SURVEYOR: CONCANNON

1. SCOPE:
1.1 Title: Lower Mast Caps; inspect and refurbish

1.2 Location of Work: Fore, Main and Mizzen Masts

1.3 Identification: Qty (3) Mast Caps


2. REFERENCES:
a. Boston Dwg. 14947, Caps for Masts

3. REQUIREMENTS:
3.1 Remove the mast caps listed in 1.3.

3.2 Inspect the mast caps and bands for signs of decay and corrosion.

3.3 Accomplish test bores of the mast caps using a 3/8 or 1/2 inch auger bit drilled to the center of the piece being tested using 2.a. for guidance.

3.4 Submit a report of the conditions found to the Constitution (M & R) Division.

3.5 Upon completion of each test bore, glue and plug each test bore hole with the same species of lumber.

3.6 Refurbish the mast caps.

3.7 Preserve, prime and paint the mast caps prior to installation.

3.8 Install the mast caps and new eyebolts.

3.9 The new eyebolts shall be Galvanized Steel.


4. NOTES:
4.1 The mast caps shall be removed prior to drydocking the ship.

5. GOVERNMENT FURNISHED MATERIAL (GFM)
5.1 Material required for accomplishment of this Work Item shall be procured by the Constitution (M & R) Division.

SHIP: USS CONSTITUTION IX-21 ITEM NO. IX-21-A-009
CONDITION REPORT NO: 0052, 0053, 0054 CHANGE NO: ONE
2-KILO NO: N/A

COAR: PCN: C340-0009 SURVEYOR: CONCANNON

1. SCOPE:
1.1 Title: Lower Mast Caps; inspect and refurbish

1.2 Location of Work: Fore, Main and Mizzen Masts


2. REFERENCES:
a. Boston Dwg. 14947, Caps for Masts

3. REQUIREMENTS:
3.1 Delete paragraphs 3.2 through 3.9 of the Original Work Item and add the following new paragraphs:

3.2 Fabricate new, Qty(3) lower mast caps using existing as templates and 2.a. for guidance.

3.3 The new material shall be Laminated White Oak.

3.4 Fasten the new mast caps using new pins with clinch rings.

3.5 Install new, Qty(18) eyebolts clenched on the opposite side.

3.6 The new pins, clinch rings and eyebolts shall be Galvanized steel.

3.7 Install new leather and lead.

3.8 Clean to bare metal the existing straps.

3.9 Prime and paint the new mast caps.

3.10 Install the new mast caps.


4. NOTES:
4.1 None

5. GOVERNMENT FURNISHED MATERIAL (GFM)
5.1 Material required for accomplishment of this Work Item shall be procured by the Constitution (M & R) Division.

SHIP: USS CONSTITUTION IX-21 ITEM NO. IX-21-A-009
CHANGE NO TWO

COAR: PCN: C340-0009 SURVEYOR: CONCANNON

1. SCOPE:
1.1 Title: Lower Mast Caps; inspect and refurbish

1.2 Location of Work: Fore, Main and Mizzen Masts


2. REFERENCES:
a. None

3. REQUIREMENTS:
3.1 Delete paragraphs 3.1 and 3.10 in their entirety from the original Work Item.

3.2 Change paragraph numbers 3.2 through 3.9 to read: 3.1 through 3.8.

3.3 Add the following new paragraph to the original Work Item:

3.9 Removal and installation of lower mast caps is accomplished in Work Item IX-21-A-034A.


4. NOTES:
4.1 None

5. GOVERNMENT FURNISHED MATERIAL (GFM)
5.1 Material required for accomplishment of this Work Item shall be procured by the Constitution (M & R) Division.

MATERIAL ORDERING DOCUMENTATION

See enclosure (3)
See enclosure (4)
See enclosure (5)
See enclosure (6)
See enclosure (7)
See enclosure (8)

MATERIAL ORDERING CHANGES
The fore, main, and mizzen mast caps are to be manufactured new.

MATERIALS PARTS LIST:

base materials:
Caps: Laminated White oak
JUSTIFICATION FOR USING LAMINATES

The lack of solid material of sufficient quality, quantity, moisture content, dimensional size and material species has required the use of laminates.

fasteners:
galvanized steel
2 3/4" x 1 1/2" x 20" long Threaded Eye Bolt, Shouldered
fore: 6 each
main: 6 each
mizzen:6 each

washer, flat: 18 each 1/4" x 4" x 4" diameter with 1 1/2" center hole.
nut: 18 each 1 1/2

1 Each
1 1/4" Threaded Eye Bolt, Shouldered x 16" long

2 Each
1" x 5" Sheave Pin Bolt
1" -10 nuts
1" lock washer

18 Each
1/2" x 1/2" x 12" square galvanized spikes

6 Each
1/2" x 1/2" x 6" square galvanized spikes

4 Each
3/4" x 16" long threaded rod with 3/4" nuts and washers

Copper:
All Caps' mortise Lower surface are covered with copper sheet to prevent water infiltration into the lower mast head tenon.

Cap Bands: Lower and Top Mast Caps
2 each 0.25" x 37" x 30" x 2.0" width with 4" radius
2 each 0.375" x 45" x 34" x 2.5" width with 5" radius
2 each 0.375" x 49" x 24" x 2.5" width with 6" radius
2 each 0.375" x 59" x 29" x 3.0" width with 8" radius
2 each 0.375" x 76" x 38" x 4.0" width with 9" radius
2 each 0.375" x 84" x 42" x 4.0" width with 10" radius

Cap Irons or Straps: Lower and Tops Mast Caps
1 each 0.375" x 29" x 3" with 6.5" drop and 1 1/2" eye
1 each 0.375" x 38" x 3" with 6" drop and 1 3/4" eye
1 each 0.375" x 42" x 3.5" with 6" drop and 1 3/4" eye

finish:
preservative: Cuprinol
primer: Interlux Primer, one coat
finish: One (1) gallon, Interlux, Blue-Glo-White, three coats.

See 1992 Procurement File for original material receipts:

MANUFACTURING

See Enclosure (9)

REQUIREMENTS:

1. Remove the mast caps.
The lower mast caps were removed as part of Work Item IX-21-A-034A, without incident or problems.

2. Inspect the mast caps and bands for signs of decay and corrosion.

3. Accomplish test bores of the mast caps using a 3/8 or 1/2 inch auger bit drilled to the center of the piece being tested using 2.a. for guidance.
 
 
The removed mast caps were visually inspected and test boring performed to determine condition of wood structure. All mast caps showed significant signs of deterioration and decay.

4. Submit a report of the conditions found to the Constitution (M & R) Division.
Condition Report(s) NO's: 0052, 0053, and 0054 were submitted. Due to the deteriorated condition of the mast caps, Work Item IX-21-A-009 CHANGE ONE was written to re-manufacture the mast caps. See Enclosure (11).

5. Fabricate new, Qty(3) lower mast caps using existing as templates and 2.a. for guidance.

6. The new material shall be Laminated White Oak.

JUSTIFICATION FOR USING LAMINATES

The lack of solid material of sufficient quality, quantity, moisture content, dimensional size and material species has required the use of laminates.

The new caps were manufactured without difficulty. The mast caps were made up as single glue laminated piece

The standard shop stationary tools were used in manufacturing. Standard power hand tools were also used; power planer, belt sander, skill saw, and drills.
tools: See TOOLING CHECK LIST

Reference (A),was used to specify the fabrication, assembly, and parts list for the new main Lowermast cap in addition to the existing removed cap.

Cap bands were mortised into each cap, 2 each per cap, and bedded with Dolphinite bedding compound.
Cap Bands: Lower and Top Mast Caps
2 each 0.25" x 37" x 30" x 2.0" width with 4" radius
2 each 0.375" x 45" x 34" x 2.5" width with 5" radius
2 each 0.375" x 49" x 24" x 2.5" width with 6" radius
2 each 0.375" x 59" x 29" x 3.0" width with 8" radius
2 each 0.375" x 76" x 38" x 4.0" width with 9" radius
2 each 0.375" x 84" x 42" x 4.0" width with 10" radius

Cap Irons or Straps: Lower and Tops Mast Caps
1 each 0.375" x 29" x 3" with 6.5" drop and 1 1/2" eye
1 each 0.375" x 38" x 3" with 6" drop and 1 3/4" eye
1 each 0.375" x 42" x 3.5" with 6" drop and 1 3/4" eye


7. Fasten the new mast caps using new pins with clinch rings.
The mast caps were made up as single piece, made-up of glued laminations. Through fastening, using 3/4" threaded rod is not required and was not done.

8. Install new, Qty(18) eyebolts clenched on the opposite side.
fasteners:
2 3/4" x 1 1/2" x 20" long Threaded Eye Bolt, Shouldered
fore: 6 each
main: 6 each
mizzen: 6 each

washer, flat: 18 each 1/4" x 4" x 4" diameter with 1 1/2" center hole. nut: 18 each 1 1/2


9. The new pins, clinch rings and eyebolts shall be Galvanized steel.
Completed per the materials requirement.

Main, Fore, and Mizzen Caps:
Sling Channel Blocks, Laminated white oak, are installed as new, attached with 1/2" x 1/2" x 12" square galvanized spikes, all primed and painted. A total of 6 spikes per channel was used, a sum total of 18.

Lower Yard Brace Irons, were sand blasted to clean bare metal, galvanized, and attached with 1/2" x 1/2" x 6" square galvanized spikes, all primed and painted. A total of 2 spikes per Iron was used, a sum total of six.


Main and Fore Caps:
The Aft End Pulleys were sand blasted and new sheave pin bolts, 1" x 5" bolts, with lock washer and nuts, were installed, 1 per cap, a sum total of two.

Pulley Brackets, were sand blasted to clean bare metal, and re-attached using 2 each per cap 3/4" - 16 threaded rod, with nuts and washers.


Mizzen Cap:
The eye bolt was replaced as new, size: 1 1/4" x 16". One (1) total. There is no pulley on the mizzen cap.


10. Install new leather and copper.
Copper:
All Caps' mortise Lower surface are covered with copper sheet to prevent water infiltration into the lower mast head tenon.

Leather:
Both the through hole and square tenon were leather lined on the interior surface. Each cap was leathered by the Rigging Department.


11. Clean to bare metal the existing straps.
Completed per material specification. All bands, a sum total of six, two each per cap, were sent to Portsmouth Naval Ship Yard to be sand blasted to clean bare metal. Each band was then galvanized.

Cap Bands: Lower and Top Mast Caps
2 each 0.25" x 37" x 30" x 2.0" width with 4" radius
2 each 0.375" x 45" x 34" x 2.5" width with 5" radius
2 each 0.375" x 49" x 24" x 2.5" width with 6" radius
2 each 0.375" x 59" x 29" x 3.0" width with 8" radius
2 each 0.375" x 76" x 38" x 4.0" width with 9" radius
2 each 0.375" x 84" x 42" x 4.0" width with 10" radius

Cap Irons or Straps: Lower and Tops Mast Caps
1 each 0.375" x 29" x 3" with 6.5" drop and 1 1/2" eye
1 each 0.375" x 38" x 3" with 6" drop and 1 3/4" eye
1 each 0.375" x 42" x 3.5" with 6" drop and 1 3/4" eye


12. Prime and paint the new mast caps.
A preservative, trade name, Cuprinol was applied. Primer, Interlux Primer base was applied, One (1) coat. The final finish was Interlux Blu-Glo-White, Three (3) coats.
finish: See Finish Check List


13. Install the new mast caps.

The new caps were pre-fitted to each new mast before being stepped. This work was done while each mast was being fabricated on the ground.

Work Item Ix-21-A-34A specifies the installation of the mast caps.

DIFFICULTIES ENCOUNTERED:
none

WEIGHTS:
fore Lowermast cap, 1600 pounds
main Lowermast cap, 2025 pounds
mizzen Lowermast cap, 800 pounds
See Historical Record File for SHOP STORE ISSUE/CREDIT CARD material receipts.

USS CONSTITUTION
 MANUFACTURING REPORT
TOOLING CHECK LIST

Item #: D-92-0009 Title: Lower Mast Caps
HAND TOOLS
XX WOOD CHISEL __ WOOD. GOUGE
__ PIN PULLERS __ PIN MAUL
XX HAMMER __ SCREW DRIVER
__ PLIERS XX VICE GRIPS
XX BEVEL SQUARE XX FRAMING SQUARE XX COMB.SQUARE
XX COMPASS XX DIVIDERS __ Tee
__ CAULKING IRONS __ CAULKING MALLET
__ JACK PLANE __ 9" PLANE HAND __ RABBET PLANE
__ BIT BRACE __ HAND SAW XX PAINT BRUSH
__ Transit __ Level
__ fid __ marlin spikes __ serving mallet
other:
 

STATIONARY TOOLS

XX WOODMIZER __ RADIAL ARM 10" TABLE SAW
JOINTER THICKNESS PLANER __ 4 SIDED PLANER
__ SHIPS BANDSAW __ BAND SAW  __ MITER SAW
__ SHAPER DRILL PRESS LATHE
__ DOWEL MACHINE MORTISER __ BUNG MACHINE
other:
 

MATERIAL HANDLING

__ "C" CLAMP __ BAR CLAMP __ BEAM CLAMP
__ HIGH LIFT JACK XX CHAIN FALL __ come-along
__ HYDR. PUMP JACK __ PORTABLE WINCH
XX FORKLIFT XX CRANE
other:
 

TOOLING CHECK LIST

Item #: D-92-0009 Title: Lower Mast Caps
 

POWER HAND TOOLS

PNEUMATIC
__ BLOCK BUSTER __ CHIPPING GUN XX IMPACT WRENCH
XX 7" DISC SANDER __ 4" SANDER XX 4" GRINDER
__ HAND SAW __ 1/2" DRILL
other:

 ELECTRIC
__ l/4" DRILL __ 3/8" DRILL XX l/2" DRILL
__ 3/4" DRILL __ 1 1/4" DRILL __ 3/8" CORDLESS DRILL
__ 1/2" RIGHT ANGLE DRILL __ HEAT GUN __ SCREW GUN
5" ORBITAL SANDER __ 6" ORBITAL SANDER __4" SANDER/GRINDER
__ SABER SAW XX 16" CHAIN SAW __ DIE GRINDER
XX SAWZALL
__ 1 HP ROUTER __ 1 l/2 HP ROUTER XX 3 1/4" HP ROUTER
__ 2 HP ROUTER
__ 4" x 4" SANDER __ 3" x 24" BELT SANDER XX 4" x 24" BELT SANDER
__ FLOOR SANDER __ SHEAR __ SOLDERING GUN
XX 3" PLANER __ 3 1/4" PLANER XX 6" PLANER
__ GERMAN PLANER
XX 9" DISC SANDER __ 7" DISC SANDER __ PORTABAN SAW
__ 7 1/4" CIRC. SAW XX 10 l/4" CIRC. SAW __ 16" CIRC. SAW
__ VACUUM CLEANER
other:

 GASOLINE:
__ 20" CHAIN SAW __ 25" CHAIN SAW __ 36" CHAIN SAW
other:
 

MISCELLANEOUS:

__ PORTABLE REDDY HEATER __ PORTABLE WELDER __ 16" CIRCULATION FAN
__ PORTABLE STEAM CLEANER __ PORTABLE GAS GENERATOR __ 12" CIRCULATION FAN
other:
 

USS CONSTITUTION
MANUFACTURING REPORT
FINISH CHECK LIST

Item #: D-92-0009Title: Lower Mast Caps
 

FINISH
PRIMER:

__ Linseed Oil __ Pine Tar
__ Cuprinol, Clear __ Cuprinol, Green
__ Aluminum Varnish __ Chrome Oxide Metal Primer
Thinned Interlux Blu-Glo White __ Thinned Interlux Black
__ Rustoleum, Black __ Rustoleum, White
__ Formula #84 __ Cold Galvanizing
XX Interlux White Primer #4279 __ Zinc Chromate
__ PRC Primer #4
other:
 

FINAL:

__ Stain, Fruit wood __ Varnish, Marine Spar
XX Interlux Blu-Glo White #4259 __ Interlux Black #36
__ Interlux Gunmetal Gray #232 __ Formula #124 White
__ Americort 70-A anti fouling Copper __ Formula #39 Green Striping
__ Mast Brown (Alcon B) Cadillac Paint __ Formula #23 Deck Red
__ Formula #20 Exterior Gray __ Formula #42 Yellow Striping
__ Formula #40 Red Striping __ Formula #43 Blue Striping
__ #5424 Touraine Spar Red
other:
 
 

TAG ISSUE

DEFINITIONS:
RED TAG DISPOSAL OF MATERIAL
YELLOW TAG INTERFERENCE MATERIAL (TO BE REINSTALLED)
BRASS/BLACK NEW INSTALLATION

NUMBER and COLOR OF TAGS ISSUED:
TAG  Quantity Date
RED  3 07/92
YELLOW 
BRASS/BLACK 3 5/95

MATERIAL DISPOSITION

Final disposition:
_XX_ conventional disposal
____ DRMO
____ presented to the Ship's force
____ presented to the museum
____ NAVHISCENDETBOS


The Lower Foremast cap was fabricated from teak. This material was re-used in the manufacture of the starboard cathead.

The Lower Mizzen and Main caps are in storage behind the Maintenance and Repair Building.

CONDITION REPORT

See enclosure (10).

PHOTOGRAPHS

See enclosure (11).

August 1992
sheet description negative # frame
1. 1 of sht 1 LOWER FORE MAST CAP -- Removed
Fore Lower Mast Cap, Lower Side 65441 15
2. 2 of sht 1
Fore Lower Mast Cap, Upper Side 65441 16
3. 3 of sht 1
Fore Lower Mast Cap, Aft Stbd Quarter 65441 14
4. 4 of sht 1
Fore Lower Mast Cap, Aft Side 65441 13
5. 1 of sht 2 LOWER FORE MAST CAP -- Removed
Fore Lower mast Cap, Fore Side 65441 12
6. 2 of sht 2
Fore Lower mast Cap, Fore Side 65441 17
7. 1 of sht 3 LOWER MAIN MAST CAP -- Removed
Main Lower Mast Cap, Upper Side 65441 21
8. 2 of sht 3
Main Lower Mast Cap, Lower Side 65441 22
9. 3 of sht 3
Main Lower Mast Cap, Fore Side 65441 18
10. 4 of sht 3
Main Lower Mast Cap, Port Side 65441 20
11. 1 of sht 4 LOWER MAIN MAST CAP -- Removed
Main Lower Mast Cap, Stbd Side 65441 19
12. 1 of sht 5 LOWER MIZZEN MAST CAP -- Removed
Mizzen Lower Mast Cap, Lower Side 65442 15
13. 2 of sht 5
Mizzen Lower Mast Cap, Upper Side 65442 14
14. 3 of sht 5
Mizzen Lower Mast Cap. Stbd Side 65442 2
15. 4 of sht 5
Mizzen Lower Mast Cap, Aft Side 65442 3
February 1995
sheet description negative # frame
16. 1 of sht 6 MANUFACTURE, Lower Mizzen Cap
Mizzen Lower Mast Cap, Getting out 90619 1
17. 2 of sht 6
Mizzen Lower Mast Cap, Getting out 90619 2
18. 1 of sht 7 MANUFACTURE, Lower Main Cap
Main Lower Mast Cap, Rough form 90619 7
19. 2 of sht 7
Main Lower Mast Cap, Rough form 90619 8
20. 1 of sht 8 MANUFACTURE, Lower Main Cap
Main Lower Mast Cap, Rough Form 90619 3
21. 2 of sht 8
Main Lower Mast Cap, Rough Form 90619 4
22. 1 of sht 9 MANUFACTURE, Lower Main Cap
Main Lower Mast Cap, Fitting Bands 90619 5
23. 2 of sht 9
Main Lower Mast Cap, Fitting Bands 90619 6
April 1995
sheet description negative # frame
24. 1 of sht 10 MANUFACTURE, Rigger cutting leather
Cutting through hole leather 94136 16
25. 2 of sht 10
Cutting through hole leather 94136 15
26. 1 of sht 11 MANUFACTURE, Fitting leather
Fore Mast Cap 94136 14
27. 2 of sht 11
Mizzen Mast Cap, fitted with Leather 94136 10
28. 1 of sht 12 MANUFACTURE, Fitting Leather
Fore Mast Cap, Fitted with Leather 94136 11
29. 2 of sht 12
Fore Mast Cap, Fitted with Leather 94136 13
2. Secondary Photographs
Please see associated task items and rigging photos on file.

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