Mast Jig FAQ

What do the jig numbers mean? – The numbers represent the diameters of the wire in thousandths of an inch. For the Lower Mast jig, the first number is the diameter of the lower mast (see figure at right) the second number is the diameter of the top mast and lower yard (for our standard jigs we default the top mast and lower yard to the same diameter). So a 45-31 mast has a .045" lower mast pole and a .031" top mast and lower yard.

Best way to cut wire/rod – We also sell the music wire that can be used to build masts. Music wire is very hard, so the best thing we have found to do the cutting work are 8" bolt cutters made by Kobalt. They cut through any music wire like it's butter (well, really hard butter).

How to glue masts together – This is mostly a matter of preference, superglue can be used but it tends to be brittle (but it sets fast). White glue can be used and while it takes time to set, it is durable. Ultimately it depends on the individual user's needs for the models.

Tips on using the Lower Mast jig – The lower mast jig will allow you to glue one top mast and one lower yard to the lower mast pole. Start by snipping and deburring the mast wires to the desired lengths (tops and yards should already be to size, as trying to trim them to correct length after gluing may break the mast). Make sure all wire is clean and free of oil or rust. Place them in the V grooves of the jig as shown in the More Info page. Since the wire is often magnetized, use a wooden rod or toothpick to adjust the wire's final position in the fixture. After placing the lower mast last (the lower mast always goes on last, and rests on top of the top and yard) you are ready to glue.