Shaping and tapering round stock.

[Tytis]

What recommendations and methods are there for shaping and tapering the gaffs, yard arms, masts etc to match the diagram dimensions/shapes as closely as possible? I don't have a mini lathe so my previous model work was all eyeballed on a disk sander. Just wondering if there is a more accurate method. Thanks for your help in advance.

 

[Zzyzx01]

There is a recent thread somewhere on SoS where builders have posted their various techniques to shape and taper mast, yards, gaffs, etc. For my Polaris build, I used calipers to measure various diameters of these pieces along the length based on the 1:1 drawings. I chucked the round stock into a drill motor. As the stock rotated, I had a couple of sanding blocks on either side and moved the blocks back and forth stopping periodically to take measurements. I used different grits of sandpaper (100, 220, and 400). Crude? Perhaps, but the end result was satisfactory and much less expensive than a lathe. Make sure to either allow extra length to the stock or wrap tape (low tack) around the end so that the drill motor jaws don't dent the material.

...henry

 

[KAYA61]

I also use the same method...

 

[WingNut]

I do the same to get roughly close, then I hand sand to final dimensions. Sometimes the stock can get wobbly as you get further from the drill, but I just find something stable to rest it against to reduce the wobble. If there's any marring from what I rested it against, a few swipes of sandpaper usually even it out.

 

[Tytis]

Thanks for your excellent inputs Henry, Kaya61 & WingNut. There seems to be a consensus for using a drill motor and/or stationary or rotating sanding disks. I have a small drill press that can hold the mast, yards etc. Holding various abrasive grits against it should give me the shapes I need. Thanks again for your feedback.

 

[AndyA]

There are a couple of threads on this bouncing around the forum. One approach, which parallels how full-size spars are made, is to not taper round stock. Start with square stock, cut the taper, make them octagonal, then make them round. Some spars have sections that remain square or octagonal. Fair winds!

 

[shipahoy]

I use a mini lathe with a customized extended base so I can stabilize the dowel at both ends. Then after marking out the tapers and any grooves for rigging I use a medium rasp to plow out the majority ( less dust ) then finish with different grits of paper. When its ready I use a hobby saw when the lathe is spinning to cut the top where marked then the bottom. Regarding any octagon sections I do them first seperately then attach
the round sections with copper or brass rods drilled deep in both pieces and c.a. ed. I file and sand the pieces to blend together. Works for me.

 

[Thomas]

There is a recent thread somewhere on SoS where builders have posted their various techniques to shape and taper mast, yards, gaffs, etc. For my Polaris build, I used calipers to measure various diameters of these pieces along the length based on the 1:1 drawings. I chucked the round stock into a drill motor. As the stock rotated, I had a couple of sanding blocks on either side and moved the blocks back and forth stopping periodically to take measurements. I used different grits of sandpaper (100, 220, and 400). Crude? Perhaps, but the end result was satisfactory and much less expensive than a lathe. Make sure to either allow extra length to the stock or wrap tape (low tack) around the end so that the drill motor jaws don't dent the material.

...henry

I agree this is the easiest and best approach. Use a variable speed drill and go slow and make sure the stock is straight so you don't get any wobble. I also use a caliper vernier to regularly check measurements. Also, use a glove on the hand holding the sandpaper because it can get hot!