I worked out the placement of the blocks for a good appearance. There would be 18 blocks on each side. The mounting holes would be on 10 3/8" centers.
I made a template to make sure the holes were all evenly spaced and centered.
I pondered what the blocks would look like. I decided a simple circular curve for the forward and aft ends of the block would work. The base of the block would be about 3". The top would be about 3 3/4". This is close to what Practical Sailor recommended.
To make this curve I set up a more complex jig. To cut the curve I shoved the block in the corner of the block holder. Only the top of the block was visible to the right of the band saw blade here. The block holder pivoted on a 1" vertical dowel. The dowel is secured to the band saw table with a 2/4 held down with a C clamp.
Here is the result of the cut.
This view of the back of the jig shows the pivot dowel.
This jig made short work of production of 40 very similar looking curves. I turned out 36 blocks in about 1/2 hour with this. I can't tell any differences from block to block.
To paint and preserve the blocks I coated the surface inside of the bolt hole with epoxy. Once initially cured and dry I sat these in the hot car all day to get a really good post cure of the epoxy.
I then sanded the epoxy burrs off and primed the blocks.
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