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The site was down for a while (thanks, Patriot Media!) so I'm playing catch-up.
I put the mast stem box on Friday.
Here is where the jib sheets were hanging up:
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Here is the solution:
I made the box out of red oak. I like working with oak - it's a little tough on the tools because it's such a hard wood, but it .has a really pretty grain structure, it holds the tooling well and it takes the sealant well.
Anyway, I had to cut the pieces to match the pitch of the cuddy cabin, then round the sharp corners. Then I routed the top edge so the sheet would roll off the box and over the mast step. The router bit I used for the top is called a "Roman Ogee" bit.
