As of Monday night here, the aluminum mandrill “mold” is still about halfway inside the mast. For a rookie, that’s a pretty anxious weekend. I spent six hours Fri night & Sat morn getting 16″ of movement over 6 hours. The company owner Ted came in Saturday afternoon and assessed the need to reconfigure his pulling machine from 1:1 gearing to 2:1. He and I spent seven hours moving gears, huge chains, etc. They haven’t done this in many years, and once we started running again the chains slipped on the drive gears. That ended the weekend progress. CE’s Joe and Will tackled it today and finally at 6pm the mandrill moved smoothly a few feet. And then a tensioning line snapped with a bang, and we agreed to splice in fresh dyneema tomorrow. We need that process to finish!!!
Meanwhile, the shop has set me up fabricating mast fitting parts. First up, the spreaders. We’re using an existing clamshell mold, with customized fabric and epoxy formulations for the strength this mast needs. Henny, it’s really great to do this work in a big, professional shop – you’d love it here :)
First is an 11oz carbon skin, then a heavy woven uni strength braid near the center, then another 11oz inner layer.
I had my vac bag running Sunday morning out on the table, but then Ted came in and fired up the autoclave so we switched to it’s vacuum system and rolled the whole works inside.
Monday morn we pulled it out and moved on to filling each half with A500 foam core.
Tonight I repeated the layup process using the same molds, now for the second of the two spreaders.
There will be five line-attachment pad eyes on the mast. Three hold turning blocks for halyards – spinnaker, reacher and jib. #4 is for lazy jacks and #5 for Cunningham/downhaul. Each gets a G10 base built.
Keith: Ted and I decided the backstays could share the padeye with the reacher halyard, and he spec’d a big diamond one for that duty. The others get the smaller round one.
CE’s shop foreman Will did one and turned me loose on the other four. This massive, accurate bandsaw will have Mike Leneman drooling – it’s amazing, cutting 1″ G10 with ease.
Speaking of Keith, I called the other day to find he and Val at sea on their excellent St. Francis 44 cat. Sounded like a good trip off NY/NJ. Here’s a taste of how that “sailor’s cat” goes, from my visit with them in June. https://youtu.be/hdvQb8yki9M