The Sage 17 boom, made by Dwyer Aluminum Mast Company, arrives at the shop as a 8’3″ long anodized aluminum tube.
Before installing hardware I first identify the boom ends, gooseneck and aft, and the top using tape and a marker. Doing this assures I don’t install hardware in the incorrect location.
The first part installed are the bails, made by Garhauer Marine, for the vang and mainsheet. These fittings work really well to align the rest of the hardware, and keep the boom from rolling as a drill the mounting holes.
Sage 17’s outhaul is internal to the boom. The system uses a two Harken blocks, a length of wire and a length of 1/4″ double braid line.
Once all the mounting holes have been made the hardware is installed using stainless pop (blind) rivets. Stainless rivets must be installed using a pneumatic pop rivet gun, as their strength is to great for the usual hand riveter.
After the hardware is installed the boom ends are assembled. Sage 17’s boom end fittings are custom and manufactured by Spyderco.
The boom ends fittings are inserted into the boom and then pop riveted in place. It is important to first shake out all the metal scrap before putting on the last end fitting.
After the last end fitting is installed the boom needs to be shaken to assure all the scrap has been removed. If not you will hear clinks and clanks as the metal bits roll from one of the the boom to the other. During the ‘hole making process’ I drill an ‘extra’ opening at the bottom of the aft end of the boom so I can shake out any last bits of metal.
The boom is now done and ready for sailing!