Hi Gill -
Some answers to your questions -
I didn't install the mast. Voyager came to me rigged as-is. The previous owner was a world-class scrounge & the spars are obviously taken from a previous boat - they're crap, but they work. 2 spreaders - made of aluminum pipe with hand-made wooden spreader tips. The boom is the same one that was on Voyager when it was a ketch. I couldn't go longer if I wanted to because I utilize the same backstays (in the "ketch" position).
I fly an asymetrical spinnaker. No trick there.
What do you mean the fuel tank is no longer usable? What could possibly go wrong with an integral fiberglass tank?? I love mine. No leaks, the weight is all down low & there is nothing to remove or repair. I have another custom-fitted tank that drops-in right below the aft cabin floor. It may not be "standard". I have shifted which tanks I use for which purpose. What was previously a fuel tank is now a water tank & what was previously a holding tank is now a fuel tank. I figure I need diesel worse than I need poop. I will, of course, have to reverse this when I bring Voyager back to the states.
Don't worry about the blisters - they're easy to fix. Grind 'em out, glass 'em, fill 'em, paint 'em... All fixed! I repair some every time I haul out.
My chain plates are stainless steel bar stock. My problem is the internal structure that the chainplates bolt to (this may be what you are talking about). I simply chip & ospho as best I can & keep the chainplates well sealed against water leakage.
I drilled & tapped & installed a couple of additional tear-drop zincs onto the rudder shoe (lower rudder hinge).
I do have an emergency tiller. The top of the rudder post is accessed thru an inspection plate in the cockpit floor. The tiller is simply a pipe that is slotted to fit the top of the rudder post & the handle is an old ax handle (previous owner again).
If you need pics of any of these things, let me know.
Bye
Rick