Building a replacement CB for an old DS1
Posted: Sun Aug 09, 2020 7:35 pm
Thanks Green Lake for the following suggestions, quoted below. I am posting in this section, hoping for any additional specific details on how to complete this CB replacement. I am comfortable shaping the blank and embedding the brass plate that engages with the pivot/handle. But I would love details on building the blank: wood and glue types and overall outline shape. I would have thought marine ply and fiberglass, but might that not be strong enough? Anyone out there built their own CB and can share that experience? All thoughts welcome.
And see image below of the CB I'm replacing.
Many thanks.
And see image below of the CB I'm replacing.
Many thanks.
If you have moderate skills working with wood, making your own CB is definitely an option. Best way to do it is to glue several strips of wood with alternating grain and set on edge to make a plank in the desired thickness. Then look up one of the NACA foil sections and use a planer and/or belt sander to shape your blank so it has a nice hydrodynamic shape. Finally, some people cut a shallow groove at the thickest part and put down strips of fiberglass reinforcement, before wrapping the entire board in a thin layer of fiberglass cloth and epoxy. You'll also need to find a way to embed the brass plate that engages with the CB pivot. Use some fairing compound for a really smooth surface and sand down well, then paint. And done.