On 11 April 1862,
William H. Webb, arguably the premier wooden shipbuilder in the country, sent a model of a large wooden-hulled, casemate ironclad with a
displacement of about to the
US Navy Department. Webb signed a contract on 3 July with the Navy's
Bureau of Yards and Docks for a ship that had an
overall length of , a
beam of at least and a
draft of no more than . His ship was required to make in still water and she was to be armed with four
Dahlgren guns in two
gun turrets, each protected by of armor, and eight 11-inch Dahlgren guns in a
casemate. The ship was to be completed in 15 months at a cost of $1,250,000. Now named
Dunderberg by Webb, the contract was amended on 27 August to specify her armor scheme. Above the main
deck, her armor was to be thick. From the main deck to a depth of below the
waterline, the armor was to be thick, tapering to at its lower edge. The ship's main and casemate deck armor was thick except at the rear of the ship. The main deck, from the rear of the casemate to the stern, was to consist of 4.5-inch armor plates that tapered to 2.5 inches in thickness.
Dunderberg was to be given a complete
double bottom and her engine and boiler rooms were to be completely enclosed by watertight
bulkheads. She was also to be provided with two
masts and the appropriate rigging. The ship was powered by two
back-acting steam engines driving one four-bladed
propeller feet in diameter, using steam generated by six tubular
boilers at a working pressure of . The ship normally carried of coal, but could hold a maximum of . She had a light
brigantine rig that had a sail area of . Her
keel was laid down before 3 October 1862 at Webb's shipyard in New York City, even though Webb was forced to use
unseasoned oak for
Dunderberg because the supply of seasoned timber had been exhausted earlier in the war. Unseasoned wood was far more prone to rot and significantly shortened the ship's life. Her hull was very strongly built with the space between her frames filled with timber and diagonal iron straps tied her frames together. These changes made her the
longest wooden ship ever built.
Dunderbergs hull was protected from
biofouling by two external layers of zinc and copper. The ship was fitted with two rudders, the primary one in the usual location aft of the propeller, but she also had an auxiliary rudder placed in the
deadwood above and ahead of the propeller. Many other changes were made to
Dunderberg while she was under construction and significantly contributed to her delays in completion. The most important of these was the eventual elimination of her turrets which began in October 1863 when Webb wrote to
Gideon Welles,
Secretary of the Navy, saying that he concurred with the
General Superintendent of Ironclads,
Rear Admiral Francis Gregory's suggestion that the "turrets be dispensed with and the casemate lengthened to accommodate an additional number of guns" Welles did not approve the change until September 1864 when he authorized an armament of four 15-inch and twelve 11-inch guns in the casemate. This was extended by to an approximate overall length of so that it now covered the aft
magazine and shell room.
showing Dunderberg'' under construction in late 1863. Note the prominent ram at the ship's bow.
Dunderberg was built with a plough-shaped ,
ram bow of which the forward were sheathed in
cast iron. Her full armament was not installed before she was sold, but gunnery trials were conducted in February 1867 with two 15-inch and four 11-inch guns. With a gun port height of , the 15-inch guns could elevate +8.5° and depress to −5°; equivalent figures for the 11-inch guns were +5° and −7°. The 15-inch guns could traverse 30° forward of the beam and 28° aft and the 11-inch Dahlgrens could bear 28° to both sides. The only significant problem encountered during the trials was that the gun deck was made of soft pine and did not withstand the force of recoil well. Other problems that delayed the ship's completion were shortages of material, labor and money. Prices for
pig iron and bar iron nearly tripled while
boiler plate and copper roughly doubled. Wages of even inexperienced workers increased between 50 and 100 percent. The
New York City draft riots in July 1863 and several
machinist's
strikes further slowed progress on
Dunderberg. Webb failed to account for these problems when negotiating the ship's contract and he repeatedly tried to charge the Navy for alterations as well as use cheaper materials to reduce his costs. He also attempted to have his contract amended by act of Congress, but he was unsuccessful. The Navy agreed to pay for some of the changes made and it also reduced the reserve amount held back in case the ship did not meet her specifications in 1865. By about 1864, both sides regarded the ship as a
white elephant; Welles wrote in his
diary that he would rather have the money than the ship and Webb was spending more money than he could anticipate from the contract. Nonetheless, he continued work on the
Dunderberg as he had very little other work for his shipyard and, most importantly, in the hope of getting his contract amended to allow him to make a profit. On 22 July 1865, he
launched the ship, now with her hull complete and about half of her armor installed, with much fanfare. The
New York Times estimated a crowd of 20,000 watched the launching. The following year, the government rejected offers by Peru and Chile to purchase the ship, both then at
war with Spain, lest the sale prejudice its
lawsuit against Great Britain for selling warships to the Confederacy. Webb did manage to get a
private bill passed by Congress in March 1867 that allowed him title to the ship once he repaid all monies advanced to him. ==French service==