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Spot · 26-08-2020, 20:38

I tried something different with the templates this time, opting for a non-dimensional scheme. I made some fingers to hot-glue to cardboard to help define the curve at the laser line for the top of plywood. The two rounded pieces will be in front of the compression post, and the middle of the sheet had just enough leftover wood to be used to fill in the last 18.5 inches between compression post and the aft end of the v-berth. I also used t hot glue gun to tack the batten to connect the dots on the curve. Next will be adding a tapered relief to the underside of the 2 larger pieces along the hull line and installing them. The final piece will be cut into sections and installed to allow for a removable cover over the head once the Porta-Potti is bought and installed.

wingless · 27-08-2020, 05:22

Looks good.

How is the fit?

Spot · 27-08-2020, 18:39

Once I did a bevel on the edge, they fit pretty good. Only one trim cut on the straight edge of the second piece. Had I checked the fit of both templates at the same time I may have avoided this, but as it was I did one at a time in the boat, crawling over the beams and reaching in to place the 'feelers'.

I was apprehensive about the bevels to the hull. Most of the run is about 20-25 degrees so I set the piece on the ground with a 22.5 degree lean and then ran the planer level to the ground. Three or four passes at 1/32" depth and the bevel was formed. Towards the bow I twisted the planer slightly to get something more around 10 degrees from vertical as installed.

Now I need to decide on a hatch scheme, primer the bottoms, mark the beams on the hull, and then attach all with adhesive and stainless screws followed by fiberglass tape and resin to the hull.

The dimensionless method was far easier and I was able to mark, cut, bevel and fit 2 pieces faster than I did a single side berth a couple weeks ago which was done by tape measure. The seam to the hull is much tighter and it should be easy to glue and glass. I am pretty jazzed by the results.

Spot · 28-08-2020, 19:38

I went out into the boat after a rain this morning and discovered some of the leaks:
1. All 4 portlights
2. Several of the screws holding on the wooden rails for the sliding cabin top.
3. Some unfilled holes on either side of the companionway in the cabin top

I went around and marked them with a blue Sharpie marker. I dug through my collection of tubes of caulk and sealants and came up with this assortment. Is the 100% silicone or the PL Marine the way to go? The others seem to be more like painters' caulks. I suppose I will learn things when we start taking them apart. I am concerned that with cracks in the frames there will be no joy in keeping them sealed.

wingless · 29-08-2020, 05:01

It would really bug me to reuse the broken frame.

What about swapping to totally different windows, like these?

Why not examine a marine supplier for suggested sealant options?

Spot · 29-08-2020, 09:49

I have been searching on the forum, people seem to like GE SCS2000 or Dow 795 as the sealant/adhesive and Re-Mov for getting rid of old adhesive. There is also mention of the 3M structural glazing tapes like B23F. I do not live close to any marine supply stores so I end up either at a big-box store or ordering online.

The old frames are basically 1" [25mm] wide plastic, 3/16" [4.5mm] thick, flat on the inside, and rounded on the outside. The glazing sits within the hole in the hull clamped by the two frames. There was barely any sealant used on the section that I took apart. I need to conclude whether to:
-find replacement frames
-make replacement frames
-switch for something different (these seem to be an odd size at 24 x 9.375" OD [609x238mm], 2 are irregular) Having opening ones would be nice...or
-make new panes and attach them 'frameless' to the outside of the hull.

The last one seems easiest at this point. I have access to CNC for making new frames but unless I piece them together it would be 8 sheets of material with significant waste. 4 new acrylics and a tube of goop or a roll of glazing tape seems faster-easier-more cost effective. PS: panes are .250" [6.5mm] thick.

Spot · 04-09-2020, 04:29

Back to the v-berth and its hatches...
I was inspired by the geometry of a pizza cardboard to consider round access hatches.
I worked up a router jig, messed with the sizes and placements, and came up with the following. I broke an 1/8" (3.175mm) straight carbide bit, it worked better using an 1/8" upcut spiral with a 1/8" to 1/4" adapter. The radiused tabs to hold up the hatches were made on a small CNC router. So far the entire v-berth deck, three larges pieces and supporting tabs, is from one sheet of plywood. Next will be attaching the tabs (glue and screws) and paint the bottoms prior to installation.

LittleWing77 · 04-09-2020, 05:12

Love how they always put a chick in the bunk (pictures in Post #45)... not like they're suggesting anything, eh?

Spot - just wanted to say you're amazing!

I'm in hopeless admiration of someone with skills like yours - and am following this thread with interest.

My only "contribution" will be: "Holy Levels, Batman!" How many have you got?

Fair winds,
LittleWing77

Spot · 04-09-2020, 17:29

Thanks Littlewing!

I appreciate the kind words. Some days I cannot seem to get anything to fit, some days it comes together nicely. Today the next steps went pretty good, thinking some paint on the bottom surfaces tomorrow.

I was so wrapped up in the repairs I did not consider the brochure for those types of implications. I did think that she must be relatively petite so as to make the boat look bigger.

I only have 3 levels and sometimes they all agree with each other.

wingless · 04-09-2020, 18:20

Looking good. Why not make the round covers have a 1" diameter center hole w/ rounded edge radius to aid finger removal?

Spot · 05-09-2020, 05:26

Quote:

Originally Posted by wingless

Looking good. Why not make the round covers have a 1" diameter center hole w/ rounded edge radius to aid finger removal?

Thanks W.
That is a great suggestion. I need something for these 6 round ones and the 2 long rectangular ones on the side berths.

wingless · 05-09-2020, 06:31

YW

The rectangular ones might benefit from a 1"x3½" rectangular edge opening, also w/ rounded edges.

Spot · 06-09-2020, 07:31

LOL Wingless.

While you were writing that, I was working on the 'ultimate handhold router jig'. Suffice it to say I would have been done sooner having done it your way but part of the fun is letting my mind wander a bit while I do this.

The jig is based on the new 1/8 cutter/end mills I got to finish the hatches and a 1.5" diameter router bushing that came with one of my routers that I had yet to try. The acrylic piece shows where the rout will end up and is removed while cutting. The dimensions were the same as you suggested but the long sides are curved to match a hand's grip.

Had I been thinking about this purely as time spent, I could have ran them all through the CNC and been done but I wanted to see if I could get it to work as a template and bushing. I got through one handhold test piece but had to tighten the router three times and switch from plunge to fixed base. After a break, I went back to painting and called it a day. I should have also make the template board bigger so as to have room to clamp while using the bigger router.

Weather looks good for sailing but I won't have crew, so maybe I'll fix a couple small things on the dinghy and give that another go.

Spot · 07-09-2020, 11:17

I put the handholds on hold to finish the framing and cut the rest of the plywood.

The middle section from the v-berth was just enough with only about an inch to spare. I made templates as before and they fit nicely. I cut the three sections so the middle one is a little too big and can be trimmed to fit after all is installed.

I came up with a framing scheme for the lift-off section for the Porta-Potti. I am leaning more and more toward removing the deck fittings and hoses and just schlep the 2-3 gallon (8-12 L) waste tank for sanitary disposal. I did not paint the pieces ahead of time as usual because I wanted the epoxy and cloth feet to sit overnight before I kept working on the deck of the v-berth. So I got to bend and twist and paint in the boat.

There is a small hope building that I will be able to finish this soon and get a couple sails in before the weather is too cold. This week is supposed to be unseasonably cold and a little wet. I wish I would have done the sealing on the portlights but I am still waffling between old and new frames.