The gussets where cut according to the templates I took from the plans. With the cardboard templates I drew a pattern on the 10mm Okoumé plywood sheet to have as little waste as possible. Thanks to the thin Festool plunge saw blade of 1.8 mm precise cuts are achievable. I left small connectors in the plywood which I have to cut out later with the Japanese saw.

The Douglas fir boards where cut to size. With the Festool plunge saw I cut the boards lengthwise with oversize in width so that they can be planed to the right size. The rods of 60mm where then planed with the Metabo thicknesser to 22mm height and 55mm width to build the frames. A few special sizes for the mast support, bowsprit etc. still had to be made. It was a heavy job and took me one noisy day in dust.