|I made these jib sheet turning block bases about 20 years ago by shaping a huge|
piece of wood and then covering it with fiberglass. I painted the fiberglass to
match the deck color.
|I recently noticed a crack in the fiberglass cover (arrow at right) and then,|
after looking more closely, noticed that they were also cracked at the
base where they mount to the deck (arrow in center).
|I made paper templates for each piece of fiberglass sheet needed to make|
the shell (outermost surface). I adhered the paper templates around
the perimeter of the fiberglass sheet to minimize cutting time.
|Different bevels were needed on the sides of each piece to properly mate|
with adjoining pieces at assembly. The amount of bevel needed was
marked on the side of each piece.
|This photo shows the beginning of the fiberglass layup inside the shell. |
I alternated layers of fiberglass cloth, 1-1/2-ounce mat, and 24-ounce
woven roving until the entire shell was filled with layered fiberglass.
|After all the layers of fiberglass, a final layer of epoxy was "floated" to|
obtain a nice flat surface. This last layer was slightly thickened with
#407 low-density fairing filler (the reason for the mahogany color).
|I constructed a temporary drilling jig that holds the turning block base|
perpendicular to the drill bit.
|All 5 mounting holes were drilled in each turning|
block base using 6-inch long masonry bits.
|The construction of two new turning blocks is complete but a lot of|
filling, sanding, and painting remains to be done.