Post
by Roamer » Mon Sep 12, 2016 2:38 pm
Sorry for the delay in replying, had family over for weekend...
To bend this, I started with a strip of metal 4" wide by 14" long. (My mast boltrope opening is 4" long.) The mast is a "Kenyon Marine al spar", the profile is "D". In cross section, this is an ellipse 2-1/4 x 3-3/4. I made a paper pattern of the cross section from a CAD drawing, but it could also be made using the loop of string and 2 nails method. I bent the strip of aluminum to about 1/3 of the profile outline just by pushing down on the ends of the strip, using a variety of tubular objects with varying radiuses as mandrels in order to get the elliptical curve. After I had the curve right, I was able to jig saw and file to the shape shown in the pictures. Both ends of the original strip were cut off, as they functioned mostly as handles while bending the curve into the center section.
HTH, George
Edit to add: no sail stop, slugs slide down to gooseneck, gooseneck slides down to downhaul cleat.