Assembly instructions
Valdivia
Order No.
1140
Stage 23, the masts
Part Description Material Dimensions No. Note
No. off
23.1 Main masthead Machined beech 12 x 12 x 170 1
23.2 Schooner masthead Machined beech 12 x 12 x 170 1
23.3 Mast cheek Plywood, ready made 3 x 27.5 x 30 4 Sheet C
23.4 Mainmast spreader Spruce 3 x 10 x 205 2
23.5 Schooner mast spreader Spruce 3 x 10 x 160 2
23.6 Nail Brass 1 x 9 8 FS
23.7 Spreader frame Plywood, ready made 3 x 20 x 54 2 Sheet C
23.8 Transverse support Spruce 3 x 7 x 22 2
23.9 Main topmast GRP tube 10 Ø x 8 Ø x 440 1 Thick-wall tube
23.10 Schooner topmast GRP tube 10 Ø x 8 Ø x 365 1 Thick-wall tube
23.11 Topmast base Machined beech 2
23.12 Ring Brass ring 12/11 Ø x 5 4 FS
23.13 Cap connecting piece Plywood, ready made 2 Sheet E, FS
23.14 Locking pin ABS 3 Ø x 25 2 FS
23.15 Tubular rivet Brass 2 Ø x 12 2 FS
23.16 Shroud hook Brass rod 1 Ø x 80 4
23.17 Sleeve Brass 2.5 Ø x 5 6 FS
23.18 Forestay hook Brass wire 1 Ø x 120 1
23.19 Jib stay hook Brass wire 1 Ø x 170 1
23.20 Mainstay fitting Brass wire 1 Ø x 80 1
23.21 Schooner stay fitting Brass wire 1 Ø x 80 1
23.22 Masthead ring Brass 9/6.6 Ø x 6 2 FS
23.23 Main topmast masthead Brass tube 6.5/5.8 Ø x 60 1 FS
23.24 Schooner topmast masthead Brass tube 6.5/5.8 Ø x 50 1 FS
23.25 Split pin Brass 1.5 x 1.5 x 25 1 FS
23.26 Split pin Brass 1.5 x 1.5 x 15 7 FS
23.27 Plug Beech dowel 5 Ø x 10 2
23.28 Peak halyard block Brass 6 x 11.5 4 FS
23.29 Split pin Brass 1.5 x 4 x 20 6 FS
23.30 Sleeve Brass 2 x 30 4 FS
23.31 Forward belaying ring Plastic Inj. 1 FS
23.32 Split pin Brass 1.5 x 1.5 x 25 3 FS
23.33 Aft belaying ring Plastic Inj. 1 FS
23.34 Main boom support Plastic Inj. 1 FS
- Cut the GRP topmasts to final length.
- Drill holes in the topmast bases 23.11, check that the
bases are an easy sliding fit inside the topmasts and glue
them in place, exactly in line. Sand the transition area of
both topmasts smooth.
- Assemble the caps from the four rings 23.12 and the
connecting pieces 23.13.
- Before gluing the caps slide the mastheads into the masts.
The remaining thick-wall GRP tube (not yet cut to length)
can now be fitted through the frame from the underside
and used as an alignment aid. Fit the cap on top, position
it carefully and glue it to the masthead.
- Insert the topmasts temporarily and fit the locking pins
23.14 - Fig. 226.
- Later, when the boat is fully rigged, the locking pin can be
withdrawn to allow the topmasts to be lowered. This
decreases the boat’s overall height for ease of transport.
- Drill a 2 mm Ø cross-hole through the fixed cap ring, glue
the tubular rivet 23.15 in the hole and splay the end lightly
to retain it - Fig. 227.
22
- Drill 1.5 and 2 mm Ø holes in the mastheads 23.1 and 23.2
as shown in Fig. 222.
- Sand the pairs of mast cheeks 23.3 to a taper towards the
bottom and glue them to the mastheads - Fig. 223.
- Sand the two mainmast spreaders 23.4 and the two scho-
oner mast spreaders 23.5 to the shape shown in the dra-
wing. Harden the ends with SP-EX, then drill 1 mm Ø holes
in them as shown in Fig. 224.
- Fit the nails 23.6 in the holes, cut them to length and splay
the ends to retain them. The purpose of the nails is to pre-
vent the spreader tips splitting. Saw 1 mm Ø slots in the
spreader tips as shown in the detail drawing - Fig. 224.
- Glue the spreader frames 23.7 to the mastheads. Glue the
mainmast spreaders 23.4 to the main masthead 23.1, and
the schooner mast spreader 23.5 to the schooner
masthead 23.2. Glue the lateral supports 23.8 on top and
continue the holes through them - Fig. 225.
- The topmasts 23.9 and 23.10 are cut from thick-walled
tapered GRP tubes. Check that pieces of 6.5 mm Ø brass
tube 23.23 are an easy sliding fit in the narrow end of the
tubes. If they are too tight, there is a risk that they will split
the tubing. Shorten the tip of the tube until the brass tube
slides in easily. Apply SP-EX to strengthen the cut area.
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