Using John O'Neil's excellent article in Duckworks Birdsmouth in Practice I set up a spreadsheet calculating the tapers, widths and thicknesses of the staves. I elected to add 10% extra diameter over JB's specified plans and used a ratio of 15% of diameter for the thickness of the staves, which resulted in 35.6mm stave width and 13.7mm thick at the fattest part of the mast.
Ripping 14mm staves |
I made a scarfing jig for my table saw which has a sliding table. This proved successful and stress free - no flying pieces and I was able to stand out of the line of fire with hands well away from the nasty parts. I had read where people had suffered injuries using scarfing jigs on the table saw, but I'm glad to report this worked flawlessly.
The glue up was quite straightforward - thanks to help from my son - thanks Harry!. We laid out the staves on a aluminium ladder which provided a straight bench and a straight side to clamp all the scarfs to, so I am very hopeful that we will have a selection of straight long staves from which to start machining the birdmouth v-notch and tapering. I am going to cut off half the taper from the width and leave the remaining taper to be planed / sanded off the stave thickness which I hope will create a more uniform creation, rather than simply having the same thickness all the way up the mast.
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