Making a Brass Traveler

The mainsheet traveler is a device that helps reduce weather helm, decreases heeling, and helps reduce the need to reef early. It’s perfect to control balance with normal puffs and lulls. The traveler runs horizontally across the cockpit, foredeck, or coach roof, and to it is attached the mainsheet or jib sheet mechanism, which is itself connecting the traveler to a boom. On smaller boats a round bar traveler is commonly found, which utilizes a round bar or tube in place of a traveler track. The round bar is fastened at the ends only, usually spanning a space above the tiller and sometimes running from transom knee to transom knee.

In another one of those sign of the times, it can be a real challenge to find sources for quality custom-grade hardware like bow plates, port lights, gooseneck slides, centerboard blocks and yes, even the desired traveler. In this episode, boatbuilder Greg Rössel will show the simple steps and necessary tools needed for a boat owner to design and construct a handsome brass or bronze traveler using 3/8” rod. Greg starts with an original illustration that he has digitally blown up to scale and printed. From there it is measuring the necessary distance between the fastening points on the boat, laying out the dimensions and shape on a cardboard “drawing board”, and making a plywood jig for bending the rod. Using MAP-Pro gas that burns hotter than propane, Greg will safely heat one end of the rod, bend it over the jig, let it cool, and repeat the process for the other end. Next, threads are cut and nuts and washers are added. Polish to taste and you are in business!