These were both glued to a 3m length of 19mm x 75mm Tassie oak, and a bit of a slot was cut in the aft metre to allow for a block to increase outhaul purchase. Using a block, I can either go for 2:1 by attaching directly to the clew, or else 4:1 by looping through the clew back to the end of the boom.
I also cut slots in the side pieces for the outhaul to exit, and finally I mirrored everything on the other side. Then I glued it up and went at it with the power plane to make a boom-shaped thing.
The ends are 55mm round,and the center section is 55mm wide by 75mm deep. The taper at the mast end is short, over about 800mm, to ensure I've got full thickness at the vang attachment point. From the main sheet attachment point to the end of the boom it tapers over a distance of about 1400mm.
The rear shows the slot for the block, about 16mm by 35mm:
This shot shows one of the outhaul exit slots nicely. With a 2:1 outhaul I simply did an exit slot on each side, each of which will have it's own cleat, meaning the authaul can be easily tensioned from either side of the boom.
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