The GX-1Mast, 20ft. composite construction.

Designed by Bob Gray; Construction by Bob Gray and Corey Hughes (owner)

April 2005—?

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Page 5 of 5

First 10’ of the half-mast mold is glued together.

Kerf-cut skin for the mast mold is completed.

West has been applied and the skin is nailed, epoxied and taped over

the internal mast forms.

Ready to apply WEST to the inside of the mold skin.

Day : 7 hours and the mast mold is done.

Day 2: preparation of the internal Basswood mast frame. Lots of cutting, planing, scarfing and WEST System.

Arranging sets of boards            Planning mast frame boards             Final filling and sanding on mold       Wetting out scarfs

                   Wetting out scarfs.                      Side butting skins.                           The mast skin scarf.                          Skins with kerfs cut.

Cutting the carbon fiber in strips.      Marking the mold with lay-up points.     Glass ready for WEST.              All tapped up for curing.

 

Bob is finally happy, my tools and garage floor are well coated with WEST!

Bob is happy

         1/2 mast wrapped around the mold in cellophane and waiting to cure.

          The first side looks really straight and well epoxied.

Laying out carbon fiber for the 2nd side and setting the hound.

Brother Kevin came from Milwaukee to help.

Left to right: planning the edges; luff tube in place; string is taped on the inside to pull the halyard through.

The center truss is in place - the hound is set - everything is taped and curing - next day the tape is removed and voila, it’s a mast!

End view of the cured mast.

Click on additional page numbers for continuing photos . Construction story and  eventual sailing

Reports will be forthcoming.

 

GX-1 INDEX PAGE 1                                                                            FUSELAGECONSTRUCTION PHOTOS PAGE 2

 

FUSELAGE CONSTRUCTION PHOTOS PAGE 3                      SPRINGBOARD AND PLANK CONSTRUCTION PHOTOS PAGE 4

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