Locate the pieces in your kit for making the traveler beam.
Glue together the traveler beam pieces with a layer of G10 (fiberglass laminate plate ~3/16” thick) on the top and bottom of the foam piece. Use thickened epoxy and light clamping pressure to adhere them together. Double-check that the parts are perfectly aligned a few times in the first hour as these types of glueups tend to slide. Let cure overnight.
Then laminate a minimum of 40oz of unidirectional tape on the top and bottom of the beam sandwich. I recommend using S- glass unidirectional tape for this but you can use carbon unidirectional tape if you are comfortable with carbon laminates. Make sure this is laminated very well.
Glue together the foam TRV post pieces to make two foam parts.
Dry fit the traveler beam sandwich and the foam posts. You want the top surface of the traveler beam to be level with the top surface of the side decks. You will need to trim the ends of the beam to fit. the posts should be just touching the bottom of the traveler beam. You may have to shave down some foam or add some foam to get these perfect. Use a pencil to accurately mark the locations of these parts on the boat. Once you like the fit, you can remove the beam sandwich and glue down the foam posts.
Use a router or carefully sand a 1/4” radius on the edges of the traveler beam. Then laminate two layers of 8.8 oz glass over the beam. It may be easiest to do this in two steps— laminating the bottom and letting the cloth drape over the sides. Let set up, trim, flip, and do the other side.
Carefully locate and glue the laminated beam onto the boat. Apply generous fillets around all contact points— min 1/2” radius. Apply at least 2 layers of 8.8 oz cloth over all the contact points lapping onto the boat hull at least 2”. All foam parts in the beam structure should have at least two layers of 8.8 oz cloth over them. Use low-density epoxy putty to fair out the beam and the joints to prep for finish.
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