Started with spar construction due to kit lead time and outdoor availability. Generally went well. I changed the 2mm radii reduction to 3mm for the mast joiner. I changed the lower mast section to be round until after the gooseneck. I would not use roving as a wrap but twill weave instead for the sprit. If I were to start over, Id add a core to the short top mast for a gennaker block (might fill with epoxy foam or make another short top mast). Instructions are very clear but leave a little to work with for ingenuity. Having a planer would make the spars far easier than just a table saw and thicknesser.
Continuation of photo backlog for this build with mast construction, scarfing, tube fitment for hardware, rebate for mast tube joiner, Epoxy work and sanding. Lots of sanding....
Continuation of backlog from spar construction photos. I would not use roving to wrap the bowsprit but a lighter twill weave instead. It's almost transparent but not quite. The mast joiner that I made in above photos ended up too large by several mm and the masking tape stuck to the inside. I specified a mainsail for Selden series 2 sail track (7mm Dia bolt rope) which subsequently became hard to source. >6 week lead time and around £30/m. So I made sames of PVC tube inside profiled Poplar. Shown is 10mmID which is slightly large but easier to source than 9mmID (75m min order quantity). I was nervous of the bare PVC tube idea as another blog I read split the tube on first outing. Having made samples in 8mm, 9mm and 10mm ID. I would suggest bolt rope dia +2mm as an ideal starting point.
I made another mast joiner as the original was very sloppy (too large). I made a separate madrel from some spare pine and wrapped around it to 10" length then cut it down to 8" post cure. The ID profile is much better than the original and the ends did not taper due to the rebate step. I would use less material in future as there was a lot of post cure sanding. I'd probably start with really light (160g) glass twill to get the profile snug and let it part cure before applying approximately 2m of 200g carbon twill. Followed by 300mm of 160g glass twill or finishing cloth. Leave rear face down to set as the run off needed sanding round afterwards.
Mast rebate trimming to fit new joining tube. Followed by joining tube sanding to match mast profile. I would first epoxy coating the main mast before sanding the carbon tube as the black dust was hard to remove from bare wood.
