Foredeck - when things go wrong
Started early in the morning - prepared “operating theater” for cutting mast opening in the fore deck.
I used my “deep access” router bit, to reach from the template all the way down through 22mm oak.
All was going smooth and noisy when, at almost the last passage, something went wrong. I suspect that I tilted the router for a moment and that was enough to cause damage.
Well, that was very unnecessary.
Luckily we live in a world where epoxy has been invented. I mixed some G-Flex and put back the broken piece. It will hardly be seen after I’m finished - and will be stronger than wood - but I had to change my plans and leave making mast partners until this repair is finished.
Instead I worked on the mast foot.
I glued it from oak and reinforced the joint with bronze screws. Wooden blocks were placed for tight fit so after the glue cured I needed to file wood by a millimeter or so to make it fit snugly on stem/keel section.
I added channels for water to escape, on both sides. Epoxy encapsulation followed.
Rudder parts got sanded smooth and glued.
Last week I prepared rudder blade pivot disc. Instead of making it from plywood I turned mine from Delrin.
Tapped 4 holes with M6.
Disc thickness is a hair smaller than rudder blade. This should give me a latitude for adjusting friction between rudder cheeks and rudder blade.
At least this is how I understand this design.