I would like one of the 50% discounted mast boots in WHITE. I will be in Dunedin in January and can pick it up from you then or you can ship it to me at:
65A Bass Point Road
Nahant, MA 01908
We cut 3 rudders today out of 1.5” Coosa. I’ll post some pictures of my process soon.
Your drawings are great.
You should try and figure out a way to get them on a Pdf.. so a clearer version can be posted on the Ensign website.
My rudders will be one piece and the attachment rods from the rudder post that I am planning to use appear to very similar to the Ensign specs.
When routing the cove for the 1" shaft, use this bit on a shaper or router table. It is cheap and may only do your one rudder. A carbide bit could be substituted. The coved edge of the board will be flat against the router table.
When drilling for the bolt and drift holes, you could have the rudder boards glued together. Then lay the rudder blank on a table with the edge that will be coved in 6" or more from the edge of the table. Place a 7/16" thick block on the table as a guide and use a brad point ship auger bit to drill the 3/8" bolt holes. The block will space the bit at the center of your 1-1/8" rudder blank. You might want to clamp the rudder shaft to the rudder blank and use the holes in the rudder shaft to guide the drill bit in addition to the 7/16" block noted above..
I found these Drawings of the rudder by Pearson in 1963 on my Google drive. I hope they help in the recent conversation.
If you purchase 5/4 honduras mahogany which will be finished at 1-1/8" thick and then fiberglass, you will end up with the 1-1/4" max thickness called out on the drawing. When sanding the wood blank, reduce thickness to account for the fiberglass skins..
Sorry, I do not know how to get these on the forum in a PDF.