Getting the stern block glued into position took some engineering and jigs. We glued the bow and stern blocks in first making sure we had the correct width (depends on sailor size and preference) at the seat position.
Next we glued in the stern structure to support the seat and tackle.
With the bow and stern blocks glued in we had our over-all shape so we cut sheets of 1/8 baltic birch marine plywood roughly to shape and glued on the bottom - lots of clamps and extra wood and aluminum force spreaders. The sheets come in 60 x 60 inch squares so the bottom is made of 3 pieces. Rather than butting the pieces together we used a 6 inch long scarfed overlap.
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