Hi, am beginning my build by making the motor pod for a foil assist and am having trouble getting an accurate profile of my north cf72 mast. I can get pretty close but not perfect (±0.5mm) and there are small gaps between the mast and the pod. I was wondering how close do actually need to get it and what methods other people have used to model mast profiles especially on tapered carbon masts?
For a alu mast of constant section - easy - people scan the mast head on a flat scanner and fit a Bezier Curve with their 3D SW.
You have a carbon mast, with a tapered section.
Using the airfoil section:
With a caliper, in 1/100th mm, if you know the airfoil section, scale four of them (two above, two below the area), loft the four sections to model the curved tapered section and substract the volume of the pod area from your motor pod with a boolean substract operation using your CAD sw.
Cheap solution: fill the gap with a putty/PU and let it set. Transfer the different thicknesses to the 3D model
More complex: use a precise scannner.
I wrote a guide here. Lots of work to get right, but a bit of fun.