A shipwright’s challenge – the hidden work keeping Duyfken shipshape. A shipwright’s challenge – the hidden work keeping Duyfken shipshape.    

Hidden beneath the varnish and paint, wooden vessels like the graceful Duyfken are complex constructions created by highly skilled craftspeople using techniques perfected over centuries. Looking after our incredible collection of floating vessels is the responsibility of a highly skilled and even more dedicated team working behind the scenes. From routine maintenance, to finding solutions to surprise discoveries, these unseen efforts help ensure Duyfken and all the museum’s vessels can welcome visitors for many years to come.

A key part of ensuring that the museum’s fleet of floating vessels remain shipshape is regularly taking the vessels out of the water. Not only is this when the team clean the hull, but it’s a great opportunity to check over every part of the vessel both inside and out. This is also when regular ‘surveys’ (safety inspections) ensure we can continue welcoming visitors onboard and sailing on the beautiful Sydney harbour.  

For the Duyfken, the most recent journey happened in late October 2025 following work conduced at the dock to remove the lines, sails and masts, which also underwent repairs over the summer.  

Duyfken was lifted from the water using a travel lift at Sydney City Marine and transported inside a shed so it would be protected from the elements during the work.   

Once out of the water, routine cleaning and maintenance began. Our team quickly identified indications of possible damage to the bow section of the Duyfken and further examination discovered rot in the apron. The apron is a piece of timber at the bow (front) of a vessel, supporting the stem. It is a key piece of the ship’s structure, and provides a surface to which other structural elements are fastened.

After excavating, cutting, chiselling and drilling, the team gained a clearer picture of the extent of the issue. It was determined that that apron would have to be totally removed and replaced.  

As November progressed, the museum team and a specialised Shipwright worked to remove the damaged timber, which proved more difficult than first expected.  Over 140 fasteners of various types had been used to secure this section, as well as pitch, tar and modern adhesives.  One especially tricky task was removing numerous large rough nails known as 'dumps' that can be up to a meter long. This was achieved using a hydraulic jack with approximately 2 tonnes of pulling force.  

Eventually, the damaged apron was removed in sections. The fact that the integrity of the vessel remains with the apron removed is a testament to the skill of the Fremantle craftsmen that built Duyfken over 30 years ago. 

As a single oak piece large enough could not be sourced, the shipwright and fleet team worked together to fashion a new apron by laminating several pieces of oak together. It needs to be shaped using templates and moulds to fit precisely into the space where the damaged timber had been removed.  

A key part of this process is multiple test fits, the first of which happened in late November 2025. Only minor modification were needed before adding the more challenging side parts of the apron ready for another fitting just before Christmas. 

While the extensive work happened at the bow, additional repairs occurred across the vessel. It was also a great opportunity for the rest of the topsides to be sanded back to bare timber for the first time since 2009 and returning it to a colour much closer to when Duyfken was launched in 1999.  

As part of the regular checks to make sure the vessel comply with safety regulations, the Surveyors requested to inspect the propeller shafts, rudder pinnacles, seacocks and valves. This work involved removing the shafts from the vessel and raise the rudder up to expose the pinnacles. Valves and other important moving parts were removed, cleaned, checked and installed back. Everything passed the exam and the vessel was approved for the next 5 years.

Back at the museum, work on the masts and rigging continued, aided greatly by the museum’s team of enthusiastic volunteers.  

Duyfken was returned to the water and towed back to the museum in February 2026.  While the heavy lifting replacing the apron was completed, many further tasks would need to be completed at the dock before Duyfken could raise the sails on Sydney Harbour once again. 

Following many more hours of dedicated work by our dedicated staff and volunteers, a key milestone was when the masts were lifted back into place in July and the task of re-rigging could commence and prepare for future sails in time for Summer.

The extensive work by our passionate team ensures that passengers will be able to continue enjoying this slice of history for decades to come.