I'm trying to locate lumber for my spars and it's driving me crazy. Case in point - the boom needs to be 2-1/4 inch square. I can't find any lumber that is that thick, so I'm going to have to laminate pieces together. Local lumber dealer has a nice selection of 12-ft long 1 x 3 boards. Problem is they are not 1 inch thick, nor are they 3/4 inch (as they used to be) no - these are a hair thicker than 5/8 inch. I put 3 together and I get exactly 2 inches. So I would need to have 4 pieces and would end up milling away most of one of the boards. Wasteful and Expensive.
I think I could get away with making the boom with a 2-in top and 2-1/4 inch sides. What about the mast? The plans call for the walls of the mast be 3/4-in, but with the lumber I can get it would be 5/8-in thick. I'm thinking that's not so good.
Right now the only other option for spar lumber is in 5/4 thickness which has an actual thickness of a hair over 1 inch. It only comes in 8-ft lengths and it costs twice as much and I'll be milling away alot of it if I use this for the mast.
Opinions?