These were fabricated from .064 aluminum sheet. The design is to have 14 holes for the mid and upper shrouds and 7 holes for the lowers. Mounting position on the deck was to center the fourth hole from forward to a 6-hole mast step. The nominal hole on the mast step will be the third hole back.
A pattern was made of heavy paper. The sheet was cut and drilled for the Pekabe 482 turnbuckles with a #27 bit. The Micro-Mart small break was used and found to be quite tedious for this gauge. A heavier brake for 17 gauge steel was used to produce crisp bends in these lengths. This can be found on eBay for a reasonable price. Also now using large rigging screws from SailsEtc for shroud connections in 2011.
The step is 3/16" Acrylic with beveled edges for lesser drag and measures 3-1/2 by 1". The six positions are 1/2" apart and the screw holes are counter sunk to not impair the mast. The screw hole between the pin positions is forward. The center photo shows the orientation with the chain plates. The nominal hole on the mast step will be the third hole back.
These are machined from Delrin and not made in this shop. The shaft is 1/4x20 and will be tapped through the deck and king plank. A clear Silicon sealant will be the only adhesive.
This piece of aluminum channel was found by a job construction manager that sails EC12's. The metal is close to .064 and though large in overall size can be cut to that needed here. It is likely to be commercial window channel. This was cut into a 3/8" square "T". The length is 3-1/2" with 7 holes at 1/2" on center.
This piece was also fashioned from the above channel and is 3/4" long to accommodate four mounting screws.
The crane is fashioned from .064 aluminum sheet and is 3-1/2" long and 5/8" wide. Other holes will be drilled for the jumper wires, uphaul and jackline when final alignment is done.
All metal hardware will be powder coated before installation.
Onto the Deck
Here, the deck hardware was installed prior to painting so the deck could be repaired should a mistake be made. This is a long and meticulous process of precise placement. The centerline fittings must be centered and the chain plates must be parallel to the centerline. If you missed it, there is a Weight and Measures Excel chart on the Hull page.