After some consideration, I decided to simply Follow The Instructions.
I made the requisite number of 2x2" blocks and 5x10" risers. I stretched a mason's line string the length of the box beam, and centered the blocks on the string, square to the string.
The instructions call for a system where you lift up the two end forms with shims, stretch the string from them, and mark a centerline on the tops of the risers. Instead, I stretched the top string from two boards screwed to the end of the box, plumbed the two strings, and brought the centerlines of the risers up to the string. They came out very plumb and level!
Lining the tops of the risers to the string was actually pretty easy. As usual, the grain of the plywood makes my eyes think its crooked.
All went great until I got to form #2.
I noticed, with the spacing that I used, that the risers aren't high enough. The bow form hits the box beam.
I actually called Joe Greenley at Redfish to ask him about this. He said that they space the risers so that the tip of the bow form hangs off the end of the box beam. For some reason, I assumed that the 10" risers would hold every form up clear of the box.
I thought of several solutions:
1. Move the stations forward, so that the bow can, indeed, overhang the box. I don't want to do this, because I can't think of how I'm going to align the bow form to center.
2. Raise the forms higher on the risers. The problem is that some of the forms aren't big enough to accommodate that much movement-I'd be attaching them too close to their edges.
3. Replace the risers with longer ones, like 13". This way, I wouldn't have to move the support blocks or the bottom string. I think I'm going this way.
I went for "option 4". I replaced the 10" risers with 13" risers, and changed the position of the support blocks. This made the forms a bit higher than I'd like them to be, but the bow form clears the box beam with a good inch underneath. I was able to align lengthwise to the string fairly easily.
The stern assembly came out quite high off the box. I used a plumb bob to align it to the string, and a mini-bracket for support.
Showing the laminated internal stems, screwed into place, later to be shaped as I go along.
The plans arrived in good enough order, except for one detail-no rocker measurements on the forms.
They came with a manual, which is as terse as Rob Macks' is wordy. It seems that Joe has a completely different system for setting up forms than I've been using-he places the form risers precisely plumb and level, then sets the forms to a uniform height. The rocker is supposed to just fall in place. I'm still thinking about what to do: Ask him for the rocker measurements (he probably doesn't have them), or just follow the manual's instructions, and experience "The Learning Curve". I ditched the Dark Star because I wasn't in the mood for meeting challenges (with probable mediocrity), and here we are with "a surprise".
In the manual, they have you placing the blocks precisely on the strongback, then screwing the risers precisely plumb to an overhead string. I'd have to do everything exactly as in the manual, to the letter.
Also, the system for the internal stems is different. He has you building up a lamination of 1/8" strips on top of the end forms, and carving it to shape, instead of Jay's cut-away technique. This may actually be a good thing, since I can use cedar for the lamination only, instead of having to make the whole end forms of cedar. However, if he doesn't have the rocker measurements for the other forms, he really won't have them for the end forms.
In any case, I could just ask him, as a shot in the dark.
