After all the work constructing the hull I was ready to hire out the spar construction. I checked a variety of sources and got quotes from $300 all the way up to $1200. I only paid $250 for my first El Toro (6197) and wasn't about to pay that kind of money for a couple of sticks! I went down to the local lumber yard and got three 14 foot 1x3 CVG (clear, vertical grain) fir boards. I lamiated the three together, then ripped them down the center, routed the sail track and relaminated them. I messed up trying to clean out the sail track with a circular saw and split the top foot and a half...so I did it again.
This time I did things a little different. Here are pictures to help explain. Don't pay attention to the grain patterns as I mixed pictures of the two different masts because the shots were better.
Even with throwing the first mast away, the mast still cost less than $60.
First step - laminate the three boards together.
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