The 8 mast staves need to be tapered to achieve a tapered mast. There are several ways to accomplish this. I prefer to build a jig, but it does require the use of a circular saw (which I borrow from my dad).
Here’s how it works:
Lots of ways to accomplish the tapered stave, but after building 2 masts, I’m quite fond of the consistency the jig provides. It’s simple to build and produces very consistent stave tapers. Next, I sanded the edges (previously epoxied inside edge) of each stave that will contact the bird’s mouth joint during glue up. I’m now ready to build the mast holding jig that will help hold things together during assembly of the mast.
Yesterday in my zeal and zest, I planed my Sitka Spruce to 3/4″. I should have left it at 7/8″ for the yard layup. These little things always happen during a boat build. They are actually part of the process. The key is to slow down and fix the problem before moving onward. Like life, unresolved issues buried alive never die, they just manifest themselves later in uglier forms. Let’s get this yard problem resolved now.
During my sleep, the sailing Gods told me what to do. I had just enough material to add another piece to the yard, making it 2″ x 2,1/4″ overall. Once cured, I dimension it to it’s proper size and shape.
While I had wet epoxy on a foam roller, I decided to roll the inside edge of all the mast staves. While still green (8 hours from now), I’ll roll on one more coat as I prepare for the mast glue up coming next week.
If you touch your boat each and every day, it will build itself right before your eyes.
I planed the rough lumber to 5/8″ for staves and 3/4″ for boom and yard (the yard should have been left to 7/8″, but I think an overall thickness of 1.5″ will be enough.
I ripped the boom to 2.75″ (1/2″ wider than the plans call for). On my last build, I felt the boom got a little too narrow in the ends (after the taper was applied), so I’m adding a little meat in these areas.
I ripped the yard to 2″ and will adjust this thickness once I begin to round it.
I rolled on unthickened epoxy and then added thickened epoxy to the mating surfaces. Then clamp and clean up the squeeze out.