Daggerboard and rudder are at final thickness after sanding and planing. Next I cut out angles at top/ bottom/ trailing edge and started shaping the leading edge of the rudder with the templates.
Finally the bulk of my time has been spent drilling holes in tiller and transom to get all the hardware aligned and mounted. Unfortunately, despite my previous experience drilling straight and true holes from gunsmithing, I drilled 2 crooked holes. Even with straight sharp bits, a drill with bubble levels, proper measurement, piece being clamped level and light drilling pressure, still crooked holes. Best I can surmise is the tiller assembly is not perfectly square to itself...So I filled the holes with epoxy & wood flour and learned some good lessons!
Getting ready to cut out holes
Bulkheads 1 & 4 inspection ports cut out. Once it gets warmer I will install them with hardware and caulk after painting.
Finally, the drilling saga...First set of holes for the gudgeon in the bottom of the picture went great, however the mistake in drilling the gudgeon in the top of the picture can just barely be seen. One trick that helped was to use the entire setup assembled to keep everything aligned.
The other essential was a drilling guide since the whole assembly does not fit on the drill press. This is a small piece of Ash drilled on the drill press then clamped in place as a guide for the drill bit.
Installing pintles on the transom.
Successful install...whew! It is straight, centered and has good clearance.
Trying on the rudder for size.