I used a chalk to mark the outline of the panel on the angled side of the cushion.
I stiched the zipper to the inner side of the fabric.....
.... and then cut the zipper-opening from the outside. Worked well, although I guess you can only do it this way with a fabric dat doesn't fall apart at an edge which is cut.
End result. Have to work a bit to get the cushion cover at exactly the right place, but it seems it will work out fine.
I first experimented with some electric guitar string as a cutting wire. This didn't work at all so I had to order proper cutting wire - a big difference as you can see on the photo below. I got quite some cutting wire left, so if anyone is interested I can send some by mail. I also have some spare frontrunner fabric (Jay sent me quite a big piece) for the rudder cassette. If anyone is interested, let me know. This stuff is hard to find (at least in Holland).
Trial fit of cushions below. A seperate cushion with lifting straps will go on top of the lid in the front bunk.
Corners are rounded. Step 1: draw a corner.
Step 2: carefully cut the corner.
Step 3: remove offcut.
End result. The cockpit floor edge looks a bit messy on this picture because the masking tape is still on.
Now it's time for the nice work: bolting on all the hardware. I'm going to wait till my friend Eelco and my brother Hans have time to come and help. They have helped doing all the dirty work, it wouldn't be fair to keep all the nice work to myself.
The mast section is a Z-spar 301. Unfortunately no wing-shaped section. Those are hard to find in Europe. Good thing about this mast it's relatively cheap (950 euro for the anodizes mast section) and light (3 kg/meter). I got a 12 meter section and had to cut it to length to fit it in my backgarden.
Trick to get a straight cut: wrap a piece of square paper around and use that to draw a guide-line for the saw-cut.
Plans have been updated: the original ruddermount is not strong enough and needs some extra glass. Here the extra glass is in place. I could have chosen the option of the side supports in stead of the glass, but thought it would be better (looking) to sand down the bog + primer and put on the glass. I checked if with the ruddercase would still fit with the extra glass. No problem.
Mold + glass + plastic on top for the wignet support. Using a piece of aluminium angle is o good way to keep the glass from lifting at the 90 degree edge. The finished support is very floppy but I guess it will be very solid once it has been fitted to the float.
I bought an old bandsaw for less money then I had to pay for the 30 cm G10-tube for the rudder. Wish I had bought it earlier. This is a fantastic tool for sawing pieces of wood and aluminium, so much better than using a jigsaw. Here is the plate for the mastfoot. 3 minutes work and almost ready. As with the parts for the mast-step it's best to drill all the holes first using a drill-press. As long as you've got all the holes in the right place, it's hard to mess up these parts.
First layer of white paint (RAL 9010) is on. Tonight I will put the second layer on. After that I only need to paint the grey non-skid to basically finish the hull.
