A Spar Is Born

3pm eastern time, 9/11. 274 lbs. 55′ long (will be losing 6″ top and bottom for 54′ final height)

The middle photo shows that the top 8′ are tapered, to save weight and windage aloft.

Getting that huge aluminum forming mandrill out turned out to be the toughest thing in this whole 6.5 year boat build. Thank goodness that hurdle was passed!

Here’s a minute of the six hours spent today finishing this job.

The sheave boxes that will hold the masthead halyard turning sheaves (blocks) were weaved and laminated today. That’s cooking in the autoclave tonight, along with the post-cure of my second spreader.

Here’s the end of Will’s process on the sheave boxes. The epoxy was brushed in at the center of the laminations, mixed to the exact resin to cloth ratio spec’d by the engineer, and it will bleed out through all the fabrics in the autoclave vac. bag process. It was a complex series of fibers, but home builders will enjoy how these guys take peel-ply to a whole new level.

And for some evening work, i got back to those padeye G10 backers. Learning to cut the coping curve to fit these pieces to the front of the mast this week.

Now that the spar is set up on work stands, I expect tomorrow we start in earnest to finish fabricating all add-on parts and make the assembly sequence plan. Good stuff and I can truly see the boat sailing again soon.

PS – boat builders or budding nautical repair types,if you haven’t mastered all things hand-layup fiberglassing and filleting, get this little boom. Russell heads up Port Townsend Wooden Boats in Washington. It was here in the shop and I read it over dinner. Sure wish I’d had it six years ago :)

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