The spar jig timber pieces were cut to size at a local joinery with my occasional building helper Darren overseeing. They did a really good job however I spent about a week just getting it more precise as this jig needs to be.

It took a lot of measuring and sanding with the larger permagrit files. I did have to remove a bit with the jig saw from the center pieces, under a 1/4″, then back to sanding. Some of it arrived spot on and other parts needed a lot of time.

I did this over several days, its a pretty funny shape after all.

The back board

Joining the back board

One of 1000 trial setups