Roger's Notes:  This point will be used as a needle to pass the cord through the sail. If it bends or frays, the point can be renewed by again cutting the end at an angle.



Pass the pointed end of the cord through the hole in the end of the boom. Pull the cord all the way through until the knot hits the boom. Sew the sail to the boom by passing the cord through the sail, around the boom and through the sail again, as shown. Continue sewing the sail to the mast in this same manner. Then, pass the cord through the hole in the top of the mast and pull it down to the cleat. Secure the cord to the cleat.





Position the cockpit deck halves on the sub-deck.  Use Slow CA to glue the mast support to the coamings, as shown here and on the plan. Insert the mast into the support. Place the mast step on the cockpit deck and insert the mast into the mast step. Align the mast in a vertical position. Holding the mast step in position, remove the mast. Glue the mast step to the cockpit deck with CA. Then, re-install the mast in the mast support and mast step. Do not glue the mast in place.

Roger's Notes: The mast is to be removable so DO NOT GLUE IN PLACE. The mast can be held securely in place by forcing a wedge of scrap wood between the mast and mast support.



Drill a 1/16" hole near the rear edge of the deck. Position the hole directly behind the mast, as shown. Glue a cotter pin into this hole with CA.




Cut a 10" length of rigging cord. Tie a knot in one end. Pass the cord through the cotter pin in the deck, through the cotter pin in the boom and back through the cotter pin in the deck. Secure the end of the cord around the cleat on the rear hatch.

Roger's Notes:  To ease further construction, un-rig this cord from the cleat and cotter pins and place the mast aside.



Remove the cockpit deck halves. They will not be needed again until the boat is ballasted, later in construction.
 

Stay Sail

You will need the parts illustrated in your manual to complete this sub-assembly. The sailcloth, the rigging cord and the cotter pins are packed in the Accessory Bag.

You will also need the previously finished mast, boom, mast step, mast support and the cockpit deck halves.



Lay the sailcloth over the drawing of the sail on the plan. Use a ruler and pencil to trace the outline of the sail on the cloth. Also, trace all of the seams onto the sailcloth, as shown. Use t-pins to punch holes through the edge of the sailcloth, where the plan shows the rigging cord passing through the sail.


                 Click on image to enlarge

Roger's Notes:  Steps #252 and #253 are to be completed at the same time.



Lay a piece of plastic wrap (I used wax paper), that is larger than the sailcloth, on your workbench. Lay the sailcloth on the plastic wrap. Brush clear urethane onto the sailcloth, covering the area outlined by the pencil lines, as shown. Work the urethane into the weave of the cloth.





After the urethane dries, lay the sailcloth on the building board. Using a sharp X-Acto® knife and ruler, follow the penciled outline of the sail to cut it from the sailcloth.




After the urethane dries, lay the sailcloth on the building board. Using a sharp X-Acto® knife and ruler, follow the penciled outline of the sail to cut it from the sailcloth.





Spread the shank of one cotter pin and pass it through the eye of the other pin to make the gooseneck, as shown.

                



Assemble the gooseneck, mast and boom. Use a small amount of CA to bond the gooseneck to the mast and boom. Be sure the holes in the boom are parallel to the mast, as shown. Also, use CA to glue a cotter pin into the hole in the underside of the boom, as shown.

               

Roger's Notes:  In this and following steps, the best way to apply a small amount of CA is to place a drop of CA on the point of a pin and then place the pin point against the parts to be joined.



Cut a 32" length of the rigging cord. Tie a knot in one end of the cord. Apply CA near the other end of the cord and spread it towards the end by pinching the cord and pulling it through your fingers. When dry, cut the end of the cord at an angle with a sharp X-Acto® knife, as shown. This end of the cord should now be stiff, with a sharp point on the end.