DONE! Whew... what a project. Not complicated, just involved as other things tended to 'creep' into the base project (what I call the 'snowball effect'). Here are a couple lessons I learned 'The Hard Way' for those of you that are currently replacing their bowsprit.
1. Instead of measuring the distance between the holes for mounting the platform, use the platform itself as a guide. If at all possible drill the holes with a drill press. I measured the distance by 'hand', double checked numerous times and hand drilled the holes. When it came to final assembly (after treating with West system Epoxy & painting the bowsprit) the platform just didn't want to fit. Trust me, it doesn't take much error at all in any of the holes for the three lengths of all-thread to become truly cantankerous when fitting the platform to the bowsprit (I could get any two of the all-thread to work but not all three, or one side but not the other). I ended up having to 'adjust' all three holes (then re-treat with epoxy) before I could assemble the platform to the bowsprit. Not much to really matter but it did fight me tooth & nail all the way.
2. I replaced the wedge 'spacer' under the bowsprit as the original one was far too old/gone. Again, the replacement was 'exactly' like the original (as measured) with two exceptions: I widened it to the width of the bowsprit (4") to eliminate the 'gap' behind the winch supports and lengthened it to the aft end of the bowsprit. I did this because all the gaps & 'pockets' created by the narrower/shorter wedge made it hard to keep dirt/gunk out of the spaces (plus making it easier to maintain the caulking. See below).
When dropping the bowsprit into position it fell right into place... Just touching the bow tang (with a 2" SS flat washer between sprit & tang) and resting nice & flat on the spacer. Although the angle of the spacer was *exactly* the same and I placed the replacement in the 'exact' position of the original spacer when I began re-rigging the bobstay and whisker stays were too short (by an inch plus) and the forestay/staysail stay was too long (!!!). Not enough to need new rigging or turnbuckles but the lesson learned was the wedge spacer (dimensions & placement) is *critical*. It couldn't have been measurably off by +/- 1/4" but it was enough to initially think I had a true disaster on my hands. Fortunately the turnbuckles had enough remaining play to accommodate the resulting gap, My conclusion is the new wedge angle wasn't as precise as I thought and/or I must have not placed the spacer in precisely the same position fore/aft as the original. And again, trust me... even 'misplacing' the spacer even a minimal amount it couldn't have been off +/- 1/2 degree for the fore end of the bowsprit to be raised enough to alter the dimensions/lengths needed for the bobstay & whisker stays. I must say, for a time there I really thought I was screwed :)
3. General lessons learned. I had to replace the bowsprit due to dry rot. My own fault having left my hank-on jib/bag 'stowed' on the bowsprit. During the monsoon season the bag stayed wet and thus created the perfect environment for dry rot. However, having dug into the project I also discovered similar damage to the caprail, wedge/spacer, anchor locker bulkhead, etc.. All due to not paying attention to caulking. Again, my fault but because it is 'hard' to get to all the places needed it is easy to put off maintaining all the various gaps/holes/nooks & crannies etc. found in/around the bow & bowsprit. Thus, my final 'trust me'... pay regular attention to that area or you might be like me and find yourself having to replace a very critically 'structural' element of your Westsail.
Finally, I have much respect for the original Costa Mesa builders for putting all the Westsails together with the precision they did.
Bottom line though, after all the headaches, cost, work, etc. my new bowsprit looks gorgeous.
