weekender boom

[markfitz]

I have an eleven foot 2x2 piece of mahogany that I'm planning on using for a boom.  I was looking for some advice on how to make it round, and whether it indeed needed to be round, or could just have rounded corners like the mast.  I tried searching the forums for weekender boom construction, but didn't come up with anything specific to how to make it.  If anyone can give me some ideas, or point me at an existing thread, I'd appreciate it. Thanks!

[ChrisObee]

I would start by using a table saw.  set the blade for 45 degrees and take the corners off the stock.  Then use a belt sander to take the corners off of the resulting piece.  This would give you a 2" thick octagonal boom.  Which by the way strikes me as a little beefy for the application.

[Frank Hagan]

You can also go with a rounded-corner boom; it doesn't have to be completely round.  Chris' suggestion for rounding it with a table saw first and then a belt sander (or you could use a block plane) is one way to get it round.  Some people take a sanding belt, turn it inside out, and make a roller with a handle and shaft so they can use a hand drill to power it; I tried it but could never get it working easier than a block plane.

[Charlie Jones]

The simplest thing to do is use a router, a 3/4 round over bit and just take the corners off, then sand the resulting wood smooth.  Doesn't need to be round.

On a gaff rig like the Weekender, a bit  heavier boom is better than a lighter boom by the way.

[PAR]

I'll second the eased corners comments too. It'll be stronger, stiffer and easier to do then fully round. It's easy to remove material, but difficult to put it back. A 2x2 sounds kind of small . . .

[markfitz]

Really? I thought the plan called for a 2x2, although the plan book is at my dad's right now.  What size should it be?

[Frank Hagan]

The plans call for a 2" diameter full round boom, or a clear Douglas Fir 2 x 3 with "tapered to 2" at the aft end, with rounded corners".  I don't know why you'd taper it.

In the mid-1980s when the Weekender plans were written you could find clear Douglas Fir closet poles that were close grained and very stiff and strong.  Now, you'd have trouble finding one you couldn't bend over your knee! 

I think Charlie's idea is probably best; you'll keep more of the wood on the boom that way, and that will make it stronger.

[markfitz]

That's what we'll do then! Thanks for the help. This is the longest project in the history of boat building.

[Frank Hagan]

This is the longest project in the history of boat building.

Think so?  Read this guy's page:  Charlie's Procrastinated Sailboat

[markfitz]

Ha! Wow.  I guess maybe my 6 years isn't so bad.  I figure we'll be done by spring.

Also, just an addendum -- the wood I have for the boom is a true 2x2 - planed to those dimensions.  So I'm thinking just rounding the edges will give me a little bit beefier "2 inch diameter"  Even then, I'm hoping it's heavy enough, because it does feel pretty light. I guess I can weight it if I have to!

[Frank Hagan]

Well, the weight probably won't matter.  The Weekender is a small boat, and its rigged so the main sheet holds the boom down while sailing anyway.  Most people think of reducing weight on the mast and boom but with a gaffer you don't need to.  With a big gaffer, you NEED the weight or have to add additional rigging like a vang, but on a small boat you'll be fine with light or heavy boom.

My boom was pretty light ... I did a hollow bird's mouth style boom at about 2 1/2" diameter with douglas fir from my parents old patio cover (I remember my father cursing the wood as not suitable for firewood, but 30 years later I was marveling at how tightly grained the old Douglas Fir was, even in the construction grades).

[markfitz]

Thanks Frank.  To hijack my own thread, is a 1 1/4" (closet pole is all we could find) thick enough for the gaff part of the mast? I think the plans call for 1.5"

[Frank Hagan]

Thanks Frank.  To hijack my own thread, is a 1 1/4" (closet pole is all we could find) thick enough for the gaff part of the mast? I think the plans call for 1.5"

The gaff itself (that's the "top boom" that raises the sail)?  I think that would be fine.

[markfitz]

Thanks.  I hope to post some pictures soon.  It's actually getting there!

[Frank Hagan]

Thanks.  I hope to post some pictures soon.  It's actually getting there!

Pictures are required!