Project Choose Your Own Adventure

[ScottyB]

used my hatch spar template to create about 12 identical spars.  thought i could speed it along by routing them out, but the router was skipping all over the place due to the various grain directions in the plywood so the first attempted spar went in the trash.  had to cut the rest out by jigsaw which took damn near forever and then fine routed after screwing each cutout spar to the template to shave off the slight overhang.

once they were all routed about equal, they got clamped and i did some freehand belt sanding to make them all exact matches.  this took damn near forever again and afterwards i felt like i massaged my eyeballs with a rusty spoon.



after sanding the ends exact i glued all of them together x2 for extra strength.  screwed together to make sure they stayed exactly lined up together + clamps on the ends.  then a test fit for shits and gigs


so far so good.  even wobbling all over a quick eyeball puts the "lip" above the edge just right so i have space to run weatherstrip.  somehow i cleared the counter by like 1/2".  as its stands i actually did my math right...trust me i'm as surprised as you are.

also shown are some self-etching primered up fenders.  got these in from etrailer.com and they should be perfect.  nice welds, good side protection.  once the temps come down again i'll get some 400grit on them and then a good coat of pewter colored paint.