Thanks for your comment. I probably cut about a dozen of them before I had matching pairs (fore and main) for two ships (8 pairs total). The first batch was the exact length of the kit rails (read - direct replacement). Then I decided to match them to campbell's plans and include the wrench and bits on the rails. That added about 1/4", or start over!
After cutting new pieces I took one and drew a line for the pinrails 1/16" from the edge, then another line for the deadeyes 1/8" from the edge. That give me about 3/32" to the bulwarks. Some of that 3/32" will be taken up with half the thickness of the deadeyes and and the diameter of the lanyards. That means you will have to, at least, reeve your lanyards and deadeyes, if not set them up, before you install them on the rails. The belaying pins can go in last! Three-sixty-fourths offset for the belaying pin line would be closer to scale, but I am shooting for the least amount of counter-leverage of the rail in order to reduce the chance of breaking it off!
I measured of the first belaying pin hole and punched the plastic with a fine punch. That gave a seat to start drilling. Even so, the no. 78 drill bit sometimes walked 1/6"! And, I ware those magnifying glasses that have a band that goes around your head, or I cannot see anything that small!
I got all my stuff through BlueJacket after shopping around. The 1/8" stropped deadeyes are no. F0203, and the 1/8" scored are F0321 at $3.74and $3.28/ dozen. The 6/16" scored bullseyes, F0340 were $2.36/ doz.
We never discussed the Mizzen deadeyes and lanyards. They are nothing like Revell represents them and will be a challenge trying to get the belaying pins to remain in a vertical position. Anyway, I plan on using 3/32" deadeyes for the top mast. On the topgallant I plan on using 1/16" bullseyes. The 1/16 bullseyes will probably be used for anything else that needs them. At 1/96 scale, there not much of a chance of getting a 1/16" deadeye. After setting up a 1/16" bullseye, just fill it with glue, paint it, and it is now a deadeye!
Good questions, Geoff! They make me think about what I am trying to do. Some of the questions you have asked; I have not even thought of yet. Keep asking and please share your progress. I am on a very slow pace, so I expect to see your finished product long before I am near complete.
Question! The photos that I posted are small; can you double click on them and see a reasonably large Photo? I used PhotoBucket!