The underside is covered with sticky tape and the holes filled with thickened epoxy.
The holes are drilled and countersunk for the securing screw heads ensuring a flush surface on the inside of the tabernacle.
The underside is covered with sticky tape and the holes filled with thickened epoxy.
The holes are drilled and countersunk for the securing screw heads ensuring a flush surface on the inside of the tabernacle.
The Boom will also be made from Queensland Hoop pine. Unfortunately, I didn't have a stock piece thick enough so armed with my trusty Triton bench saw and thicknesser I set about making some dust.
I laminated two pieces together which is a bit more labor, but I think a laminated boom is stronger.
The timbers are ripped down to size.
Time to create some dust...again.
The Gaff or Yard whatever you like to call it will be made from Queensland hoop pine. Beautiful light-colored timber straight grained and no knots.
I was lucky that the stock piece I purchased was the exact thickness so all I had to do was cut it to length and shape.
A batten is bent in place over the measured marks and a pencil line drawn.
A small circular saw easily cuts along the curve.
The timber planks on the floor to the left of this pic is for the mast and boom.
The curve is cleaned up with a belt sander that I fixed to a bench.
The edges are routed and the complete unit sanded smooth.
Using a level the gaff is set up on a drill press. Larger diameter holes are drilled to fill and re-drill for the Racelight Gooseneck.
Same for the eyestrap holes that will support the block.
And lastly the hole on the aft end that lashes the head of the main sail.
Well, I couldn't help myself, after seeing how the blue gum inserts looked on the boom, I decided to include them on either side of the gaff.....more work.
So out with the router and in with some blue gum inserts. Here they are clamped in place until the epoxy sets.
Clamps off and time to clean up, I used a handheld belt sander followed by an orbital sander and finished off by hand sanding.
I decided to trial fit the rudder prior to flipping the boat. I remembered reading reports from other owners that indicated noisy rudders when at anchor.
I did some measurements and found the eyebolts were15mm internal diameter whereas the pivot rod was 12.5mm diameter.
This resulted in a 2.5mm gap which I guess was causing the noise.
I did some shopping around at various shops that sell 316 SS eyebolts and found that "Anaconda" stocked eyebolts that were 13 mm internal diameter....perfect.
To further strengthen up the complete rudder setup I added an extra eyebolt pivot point between the existing two.
To reduce the friction and any further rattling between the heads of the stainless-steel eyebolts and the pivot rod I decided to add some washers made from "Starboard".