In this series of photos, I'll just show some basic steps in the assembly process. The marking and cutting of the staves which make up the spar need an article of their own.
Because of the large surface area which needs to be covered with epoxy, time is critical, and you need to be organised!
|First four staves laid up dry to test fit. I am using 'U'-shaped plywood forms to hold the staves loosely together and in alignment. The forms are clamped to a long piece of timber acting as a strongback.|
|I always make solid inserts for the bottom of the mast. It usually extends up to above the level of the mast partners. The internal 'V' cut-out is there so that there is no abrupt transition in stiffness between the solid and hollow sections.|
|I carefully shape the solid inserts so that they fit the internal shape of the mast without holding the staves apart. A slightly loose fit is good, as it allows a rich glue-line between the insert and the inner walls of the mast.|
|Another view of the insert|
|This shows me working on another mast. We had already applied the glue to the gluing surfaces using various techniques, and at this point I was rapidly adding extra where required, and was smoothing the glue on all mating surfaces|
|Start with a few, evenly-spaced cable ties, and then put on more in-between.|
|I use high-quality cable-ties and tighten them with the aid of pliers.|
|Here is a finished mast on another boat I built a couple of years ago.|