Spring is upon us, so it must be time for yard work.

Yard work. Hmmm. The garden is about to come alive again, but that's another story. With the mast finished the table is clear again and I can begin the yard. The spar is tapered from the center to both ends. Finished, it will be 18.5' long (5643.11mm), measure H4.375"(112.86mm)xW2.875"(73.36mm) at the center (and extending 10"(254mm) either side of the sling point, and H2.875"(73.36mm)xW2"(50.79mm) at the ends. The bottom is flat. There are 4 planks side-by-side and a bottom piece to be glued together. It was the best way I could think of to get the straight, flat bottom on the spar. The mast is finished except for priming and painting. Might as well do all of that once.


Mar-13 - This might explain what's happening more succinctly. These are the sketches I took to the basement once all the number crunching was complete. (The 5.4" is in decimals +/- but I stuck with inches. The millimeters are for the rest of the world that uses rational nembers. The numbers at the lower left are the sail in square meters.)


I have quite a few long boards left from the mast building. I picked the best looking ones first, widest and longest.


Mar-14 - I've started surface planing slightly tapered sticks to get flat planks. Next, I power-planed the needed scarfs to get length.


Mar-15 - Scarfs gluing up. The ones at the back of the table are finished.


Mar-17 - All 5 planks glued and re-surface planed to smooth, flat faces for the glue-up. Note the pile of sawdust getting deeper. I stretched a stringline from end to end on each plank and marked points at 4' intervals to "pencil" on the flat bottom of each standing plank. Then I hand planed to the line. Result: an extremely flat edge to glue to the bottom plank.


So as not to get confused, I marked each plank prominently. The arrows indicate the trued bottom edges that will sit on the bottom board, called "BOT". Once I was satisfied that everything so far was going according to plan, I laid on a coat of straight epoxy and let it soak in. Later I came back and recoated the "dryish" areas. (Some parts soaked up more than others.)


After a couple of 2-cup batches of epoxy loaded with Cabosil were spread around, it was clamp time. My brother was there to help with picking up the planks and holding things together as the clamps went on.


Mar-18 - Clamps off; a straight, true beam ready for surface planing to "rough" size. It needs 4 square sides in order to layout the tapers. The table was spotless for glue-up, but I got carried away after taking the clamps off and rushed in to hand plane "A", on the right, because redwood is so much fun to plane.

Took a little break to write this page.


Mar-19 - Here, all 4 sides are planed and the groove for the stainless track has been cut. The track will stand just a bit proud of the bottom surface... more than a 1/16th" but less than an 1/8th". I could have taken a little more care setting up this photo. The track is ever so slightly twisted until it's screwed in place.


Mar-20 - The top tapers are about to be bandsawed. Marked off the offsets from center, marked the ends, and remembered belatedly about the 10' piece 1" square stainless tubing that's dead-straight that I use for such occasions as this. I sawed the tops to within a 1/16th", then beltsanded to the lines.


Upside-down... and from the opposite end of the shop.
The top tapers were cut. As you can see, the side tapers are much narrower. Instead of trying to use the bandsaw, I marked both the top and bottom edges so I could plane and sand these tapers to the lines.


A rare view of the shop from the far end. The reason most of the photos are shot from the other end of the shop is that the stairs are there and it's moderately cleaner to take a snap and leave the camera there... out of Goop's way.


Mar-22 - Hand sanded three sides yesterday with a longboard to get smooth surfaces for the router to skim over.
Routed the roundovers this morning. All went well until one section took a huge divit out. I was disappionted but not heartbroken. It just means I'll have to apply some faring goop and resand the spot. Then I recoated three and a half sides. I'm waiting until I can turn the spar over to add another coat to the track groove since I don't want it to form drips that take even more sanding. The ends aren't quite finished either. There's a slot to be cut in the ends that I wasn't prepared to tackle today.

Mar-23 - Started Secret Project.
Glued up the replacement garden bean poles, but only one at a time, since I have only so much surgical tubing to tie it together. That's it, above to the right of the spar. Ever since cutting the birdsmouth in the mast staves I've had these bits of scrap - tapered half-squares. Call me cheap but I've been reluctant to throw them out because they're redwood. And until now never had a use for them. Gluing them together produced square sticks that when roundedover will replace the bamboo poles I get from the neighbor that rot away every year.

Mar-24 - More Secret Project.
Glued second of the three garden poles first thing. Stripped off the surgical tubing ties and glued up the last stick.

Mar-25 - Finished cutting and mortising Secret Project. That took most of the day.
Beltsanded the bean poles to get the glue goobers off and rounded over all four sides. Then slapped a coat of goop on to seal them up. Bellissimo!
Bought fender tubing.

Mar-26 - Assembled Secret Project.
Built scarf sled.

Mar-27 - Rasped rope slots on the ends on the yard. Sanded spar. Cleaned the spar with alcohol. Epoxied the bottom half.
Sanded and epoxied S.P.

Mar-28 - Coated S.P.
Fabbed "sling plate" plates. The sling plate is what the yard hangs from.
Mixed up some fairing goop, epoxy and phenolic bubbles, and filled the nasties the router produced all along one corner of the yard.
Ordered paint from my friend, Chuck, at Duckworks - WR-LPU. Primer too.


Mar-29 - Made up a cacrificial block to screw the plates to so that I can weld the bail on without a lot of fuss. Fitted bail to sling plates. The "bail" is jewelerese for the loop.


The masthead light bracket made from a stainless pot bottom seemed like a good idea at the time. For the life of me I couldn't remember where I'd stashed the 1/8" plate I knew I had. That was to be the original material for the bracket; substantial, not the least flimsy. It turned out I'd been dragging it around in the back of the car for so long, it just looked like it belonged there. And I couldn't "see" it anymore. The pot-bottom bracket really was wobbly and it bothered me no end. All's well that ends well. The screws are temporary clamps to keeps things aligned until welding is complete.
Since I had the material handy, finally, I sawed the plate for the metal partners, see Practical Junk Rig, Chapter 9.
Aggy takes a bow for making sure I did it right this time. She's such a good helper.


Mar-30 - This is the last time you'll see this yard naked. Sanded the fairing compound this morning. Went off to the shop to weld the sling plate and masthead fitting. I've done prettier welding but they're both servicable. Then I cleaned the yard with naphtha. Once it was dry, not long really, I made up a batch of thinned-with-zylene epoxy and coated all sides. The paint is arriving Friday. It should be nice and set by Sunday when I plan to paint.


Voilą, the Secret Project!

If this hadn't come together well, and it was doubtful for a while, I was fully prepared to deny having ever mentioned it. But, as it turns out, it's going to be quite nice in the well of the cockpit.
I've been wanting a "ship's grate" for the longest time. First, I contacted a local custom teak furniture manufacturer about a quote. They simply blew me off. Several months ago, I contacted them again. This time they did eventually return a quote. And I nearly had my second heart attack. So, I forged ahead on my own... again.

Mar-31 - Today was Stay Away From the Yard Day. It needs to cure for another day or two, so I busied myself with some other things.
One of the reasons I started finding excuses for not getting on with it three years ago was that I started making mistakes. My measurements were off and the final product was inelegant. The gimbal for the stove was one of those atrocities. So, on my last trip to the shop I picked up the stove and the botched gimbal and brought them home. Today I recut the outside frame, deleted the middle frame and tweaked the inner frame. The new version won't swing in all directions like the original, but it took way too much room on the galley counter. It will swing from side to side... like all the others out there.


I call this the Old Man's Friend. My brother found some 99-cent LED flashlights. After some pestering, he finally parted with one. It's going to make close cuts with this sabersaw a lot less frustrating for these poor old eyes. After several attempts to get the mounting to stay put on the aluminum of the saw housing, I remembered Lisa's magic glue, E-6000, very much like hotglue, but it really sticks and it comes in a tube.


Notice how clean my benchtop is.

During the last month or so I've cleaned 60+ bags of trash out of the basement. That's what can happen when you stay put for eighteen years. During the course of one foray into the clutter, I rediscovered these latches. Up until now I'd been planning on installing some little plastic buttons/grabbers on the doors and drawers to keep them from swinging or sliding open in a seaway. Now I'm just hoping I can install them without too much tinkering. I seem to recall rounding-over all the doors and drawer edges. These have a hard corner. I may just have to solder tiny kant strips into the inside corners and rounding-over the brass corners because I really like them.

The garden bean poles are finished and standing in the garden.

And so is this page.

This way to --> April.

This way --> [home2.] Home.[chaos]

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Written 2011/Mar/18

Updated 2011/Mar/31