Hull offset stations and centreline were projected inside the hull and 6mm ply stringers glued, coved and glassed in.  Mountings for the aft cockpit bulkead ( to give maximum aft deck length)installed.  Transom stiffened and supported. 

Stringer grid completed with cockpit aft bulkhead and side tanks installed. Supports for the floor join, hiking stap mountings and mainsheet block glued and glassed in.

Stringers needed too be this close together to allow the floor to be made from 6mm plywood.  The floor is the heaviest and biggest single piece of construction material.   It has to be strong enough to take the helmsman weight.  

Centrecase capping strengthened and lengthened with cedar and carbon fibre.

To give maximum stiffness, station 3 and 4 bulkheads were glued, coved and glassed to both the side deck and inside hull. Station 5 bulkheads are fully glassed to make the whole aft end of the boat a bouyancy tank.

Bundles of closed cell foam rods (the stuff kids use in swimming pools) were hung in the side tanks to provide positive bouyancy in case the aft tank is breached.

Foredeck stringers (cedar) installed and glassed to the foam hull stringers. Front centrecase supports go directly to the inside hull/deck join and hence the gunnel.

Gunnels (not shown) was made from 4 strips of 6mm ply bend around the exterior deck/hull join and screwed, glued, glassed to form a very stiff, solid foundation for transferring the helmsman righting momentum into the fordeck.

Bottom mast step installed. Adjustment is by 10mm blocks (plus a 5mm one for fine adjustment). Same thicknesses as the top mast step adjustments.  Makes it easy to move the mast forward or backwards in the boat without losing mast rake (leech tension) settings.

Centreboard slot supports in the case was constructed from high modulus carbon fibre offcuts. Centrecase needed extending to enable the centreboard to slide the 20mm fully forward.

Bolt is 10mm and had a lug welded on later to prevent rotation. Adjustments requires only one spanner.

Because of the reduced centreboard arm area as prescibed in the 2005 rules the centreboard slot position required much mocking up (in full size cardboard templates) to get it to fit in the centrecase.  Centreboard was maximum size.

Too high a centreboard bolt position while giving the desirable as close to vertical leading edge, resulted in the top end of the trailing edge chord projecting below the hull. Too low a centreboard bolt position and the centreboard arm would project below the centrecase capping. With 10mm to play with the best position ended up being 45mm above the keel.

Even in this position the amount of centreboard above the capping was minimal. Made it difficult to install a stop plus allow for pulley and bungee cord mountings.

Biggest decision to be made while designing the rebuild was whether to go with the open front cockit (Devoti style) or a closed cockit one (Vanguard/Lemieux style). Decided on a closed cockpit to keep stiffness in the boat plus save weight.

There doesn't seem to be a need for a false floor along the centrecase so these were left out to save weight as well.

Thwart was fabricated on the curve of the old traveller from 3 layers of 6mm plywood.  Screwed, glued and glassed to the centrecase in maximum aft position with the ends screwed, glued and glassed to pads on station 4 bulkheads.  Thwart acts as a stessed member of the hull to transfer loads from the helmsman and centrecase into the boat.

Rebates in the centrecase capping are for plastic inserts that will keep the centreboard in a vertical position and make lifting and lowering easier by reducing the contact area.

Cockpit coaming was fabricated from cedar.