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Dan Kulin working on rig design
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Extrusions before splicing and tapering
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Extrusions before taper and splice
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Extrusions before tapering and splicing
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The taper is cut out of the section
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Cutting the taper
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Cutting the taper
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The taper is closed with clamps prior to welding
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The strongback is attached to the section with taper. The strongback keeps the weld from warping the section.
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The strong back is attached when the taper is welded to keep the section from warping.
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Splice doublers ready to fit
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The doubler is welded together
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The doubler ready to fit
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The doubler is placed inside the section
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The doubler is fitted and holes drilled for plug welding
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The doubler is fitted inside the section before welding
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The two sections are put together with a doubler then welded
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The extrusions are fitted with a doubler and plug welded together at the splice. Later the lower spreaders will be attached in this location.
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Three new spars after splice welds
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Pattering for the mastheads
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New mast heads
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Welding the masthead
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The masthead is welded to the tapered end of the spar
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Mast head is attached to the spar
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Masthead completed
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Fitting the staysail lug
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Inner forestay tang
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Cutting the spreader through-bar slot
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Spreaders are tapered. Tips are welded on.
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Fitting through bars for the spreaders
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Tang backing plate donut ready for welding
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Porting for halyards
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Sail track is filled with epoxy below deck for clean look inside the boat
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Filling for paint
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Ready for paint
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After paint
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Electrical to masthead assembly
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Vang tang attached with 1/4 mono bolt rivets
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Double tang for lowers
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Assembly
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Six sheave mast head comfortably accomodated plenty of halyards for cruisers
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