Turning the Mast and Spars

I wanted to make my own mast and spars, and I had a few special requirements, or modifications that deviated from the original plans.  I wanted the simplicity and the different look of the balanced lug rig.  While the plans provided specifications for a balanced lug, it was, shall we say, dinky.  I knew that this was no racing boat, but I also did not want to be passed by grannies on paddleboats either.  So, with the blessing of the designer, and cooperation with a sail maker, we changed the sail area from 56 sq. ft. to 90 sq.ft.  The man who built the sail for me designed it to fit on the specified mast.  This made for a very sinister looking balanced lug, which will appear on these pages in due time.  But, the size of the sail was not the only change I made.

Both the original and the modified sail plans showed the boom sweeping over the deck about 18 inches above the gunwales at the "pilot's" position.  Being a very large sailor, and preferring to have more visibility, I decided to make the mast longer.  This way I wouldn't have to duck when coming about or gibing.  I would also be able to see what was going on over to the leeward side of the boat.  Again with the blessing of the designer, I increased the mast in height from 11'11" to 14'2".  I'll explain the 14'2" momentarily.

Along with an increase in height, I needed to increase the cross section of the mast.  It wouldn't do to put all that work into it, just to have it snap off in the first stiff breeze.  I used the book Practical Junk Rig as a guide for scantlings.  The writers specified a mast with a cross section of almost 6"!!   That sounded awful heavy.  Of course, these guys are writing for traveling across oceans, and in the text they confess to overbuilding the scantlings. What I ended up doing was increasing the mast cross section by the same percentage that the sail area was increased, and then adding a little for safety.  I ended up with a mast with a cross section of 3 1/2" at the partners and 2" at the top.

From the beginning of the project, I was searching for wood for the mast.  I could not find Douglas Fir anywhere, except for stuff that was soaking wet.  However, if I had purchased it right off the bat, it would have been ready to glue by the time I was ready to glue it at the rate I was moving.  I briefly considered Sitka Spruce, but there were problems, not the least of which was the price.  I would also have to have it shipped by common carrier, and after managing a few warehouses, I was not about to let something that expensive and that fragile be handled by the types of people I had encountered at the loading docks.  Then I thought about my friend in the millwork business.  He had lots of mahogany in stock.  Mahogany has a fine maritime tradition, so I gave him a call, and he sold me some wood at a very reasonable price. 

Here again is a choice I made that will probably offend someone out there.  Economists will be quick to point out that it is too expensive.  Tree huggers will point out that it is endangered (I don't necessarily agree, but that is another discussion).  Others may wonder why I splurged on this when I allegedly "skimped" on the hull.  I will say this.  First, the price I paid was VERY reasonable.  Second, I wanted to do the trim bright, and a little on the fancy side, as this is the first boat I have built, and who knows if I will ever get the chance to build another?  I plan to, but no one knows the future...

I also wanted to turn at least the mast on my lathe.  I was told by a number of people that I could not do it, and all that did was increase my determination.  Well, if you are one of those unbelievers, read on.  I did it, but I can also say that I had LOTS of help, and I could not have done it alone.  Well, maybe I could have, but it would have taken a lot longer, and I probably would have suffered drastic setbacks along the way.  As it turned out (ha ha), it was a great adventure for all involved, as well as a lot of fun.

But enough of this talk.  On to the pictures.