The estimated sums to build a battery 130 feet long, with a 50-foot beam, capable of a speed of 5 mph, and carrying 24 long guns (18-pdr.), was $110,000. Fulton, still the chief engineer, in an effort to interest the Federal Government, built a model of the proposed vessel and submitted it to some prominent naval officers—Commodore Stephen Decatur, Jacob Jones, James Biddle, Samuel Evans, Oliver Perry, Samuel Warrington, and Jacob Lewis. All gave their support to the Society in a written statement and this recommendation proved helpful to the project in Congress and in the Navy Department. In the process of passing a bill which went to the Senate Naval Affairs Committee calling for $250,000 for the construction of the floating battery, the sum was raised to $1,500,000 for the construction of “one or more” floating batteries and passed on March 9, 1814.
To supervise the start of construction, the Coast Defense Society appointed a committee consisting of Dearborn, Wolcott, Morris, Mitchill, and Rutgers, with Fulton as engineer, and a model and drawing of the proposed vessel was submitted to the Patent Office. The Secretary of the Navy, although supporting the project, delayed action until he had weighed the importance of the batteries in relation to other war needs, for at this time the naval shipbuilding program on the Great Lakes was considered of prime importance. He also raised some technical questions concerning the design of the batteries, which Fulton answered with a description of the vessel as 138 feet on deck, 120 feet on the keel, 55 feet beam (each hull to have a 20-foot beam and the “race” between to be 15 feet wide), draft 8 or 9 feet loaded, and the intended speed was to be 41/2 to 5 mph. The ship was to carry 24 long guns (32-pdr.), the engine was to be 130 hp, and the total cost, $200,000. In his letters to the Secretary of the Navy, Fulton stated that Adam and Noah Brown would build the hull for $69,800 and that he would build the engine, machinery and boilers for $78,000, a total of $147,800. He intended to have the boilers, valves, fastenings, and air pumps of brass or copper, which would raise the machinery costs 59 percent above that of stationary engines and boilers then in use.
On May 23, 1814, the Secretary of the Navy authorized the Coast Defense Society and its committee to act as Navy agents and to enter into the contracts required to build a vessel, and to draw on the Navy storekeepers or Navy Yard commandants for such stores or articles on hand needed for construction. The contracts were prepared and the committee now was officially empowered to act for the Society, with Rutgers, Wolcott, Morris, Dearborn, Mitchill, and Fulton. On June 4, Dearborn asked the Navy Department for $25,000 advance, for work had started. On the 6th, he informed the Secretary that he had been ordered to assume command of the defenses of Boston and that Rutgers had been appointed chairman of the construction committee in his place.
It is apparent that the Navy Department was pressed for funds, due to the very extensive shipbuilding programs on Lakes Erie, Ontario, and Champlain in addition to the seagoing vessels being built in some of the coastal ports. This was certainly one cause for the Secretary of the Navy’s reluctance to carry out the requirements of the bill passed by Congress immediately after its signature and, also, this reluctance caused the supervisory committee much embarrassment in its administration of the contract.
Another factor which caused difficulty in the administration of the contract was the position of Adam and Noah Brown. The brothers were deeply involved in the shipbuilding program on the Lakes, in which they were associated at times with Henry Eckford. The Browns constructed a blockhouse, shops, and quarters at Erie; in addition to Perry’s two brigs and five of his schooners, they also built some of the Lake Ontario vessels and, later, the Saratoga on Lake Champlain. In their New York yard, whose operation continued throughout the war, they built some large letter-of-marques: the General Armstrong, Prince de Neufchatel, Zebra, Paul Jones, and some smaller vessels. They also cut down the 2-decked, merchant ship China into a single flush-deck letter-of-marque, renamed Yorktown; and they had a contract to build the sloop-of-war Peacock. It is remarkable that the Browns could undertake and complete so much work between 1813 and 1815 and still be able to build the steam battery in a very short time.
With the contracts in order, the Browns began building. The keels of the battery were laid June 20, 1814. It is apparent that the Browns prepared the original hull plans, undoubtedly before the building authority was obtained. The vessel required only about four months to build; she was launched October 29, 1814, at 9 a.m. This was an excellent performance, considering the size of the vessel, the amount of timber required and handled in her massive construction, and the other work being done by the builders. During the ship’s construction, sightseers were a nuisance and finally guards had to be obtained. During the building of the steam battery, work had to be practically stopped on the sloop-of-war Peacock at one period after she had been partially planked.
There were difficulties in obtaining metalwork for the vessel during her construction, due to the blockade and the demand for such material for other shipbuilding at New York. On November 21, 1814, the ship was towed from the Browns’ yard on the East River by Fulton’s Car of Neptune and Fulton, each lashed to the sides of the battery, and taken to Fulton’s works on the North River. There Fulton supervised in person the completion of the vessel and construction of her machinery. Undoubtedly only a little of his time was required in inspection of the Browns’ work on the battery, for the shipbuilders had been closely associated with Fulton throughout the life of the project and were fully capable as ship designers. The work on the machinery was another matter, however, for men capable of working metal were scarce and few workmen could read plans. Fulton had some of the work done outside of his own plant, particularly the brass and copper work (mostly by John Youle’s foundry). As a result, Fulton was required to move from plant to plant, keeping each job under almost constant observation and personally supervising the workmen. The equipment then available for building a large engine was inadequate in many ways. The large steam cylinder presented a problem: it had to be recast several times and some of the other parts gave trouble, either in casting or in machining and fitting.
