I know I've covered a lot of this material on my catboat thread already, but there's still plenty more to do. I think that a separate thread would be a good idea so the process is available to anyone interested without having to hunt for it.
Please bear with me here while I get this thread up to speed. I'm finding it a very interesting project and hope it will give others some good ideas.
I'll start with the mast band patterns, because they are already in the finishing stages. The end fitting for the boom is being worked on at present and I will get to that shortly. There will be an intermediate fitting that hinges on the mast bands and connects to the boom end fitting. That pattern has not been started yet.
So, here we go. The mast band patterns will begin with two laminations glued up on a round form. The wood is Alaskan Yellow Cedar, a less than ideal choice for patterning as it turns out due to it's grain structure. Patterns are best made from a very mild, smoothly grained wood of intermediate hardness. Cherry, Spanish Cedar, Honduras Mahogany are all excellent woods to use.