Bits and pieces

Jessie tackled cleaning all the old sealant off of the window frames. It was a tough job but he stayed with it and got-er-done! Thanks Jessie!

While he was working on the frames I sanded the old wood coamings from the cockpit.

It was quite soiled and I wasn't sure how it would turn out. I used the Fess sander / vac combination and started with 40 grit paper and worked up to 320 grit. It came out looking fantastic!

The Fess sander is a very high quality unit that I inherited from Dennis, a fellow boat-builder and friend who died of cancer last year before he was able to complete his beloved vessel. He was a fine craftsman and was far more skilled than I am at woodworking. His custom built laminated wood hatches, counters, and tables often had beautiful little accents and features built into them that made each one a work of art.

 He kept a good attitude right to the end and encouraged me to finish my boat.....we aren't getting any younger and when our time here is up.....we're done. We miss ya Dennis.

 

Settee Cushions

Now that we had the bunk foam cut and test fit I started pondering what we would do for the back rests.

On my previous small vessels some had one piece bunk cushions and some had a two piece arrangement making it easier to access the lockers below. I quickly learned that the two piece was uncomfortable too sleep on and I much preferred a single bunk cushion. When lying on my back in the bunk the backrest cushion was in the way narrowing the width of the bunk just enough to be very annoying. I used to toss the backrest cushion into the V-berth at bed-time to give a little extra room on the bunk.

So I decided on this vessel I would keep the bunk cushion as one piece and make the backrest cushion a partial that would leave the lower section open and provide a little more width for sleeping.

The drawback to a long bunk cushion is it flops around when trying to move it or gain access to the lockers below it. A good way to solve the problem is to mount the cushion to a thin sheet of plywood.

It makes it far easier to move around and when the cushion is lifted to gain access below, it acts like a locker lid and "hinges" up nicely and takes little effort to hold it there while digging in the locker.

The bunk cushion was laid on a quarter inch thick sheet of plywood and the outline drawn onto the wood.

The wood was trimmed a half inch on all sides to allow for the wrapping of the upholstery.

The foam was then glued to the plywood with contact cement.  Half inch thick low density foam with a scrim was rolled out onto the work table and the cushion was inverted onto it so the plywood bottom was now on top.The foam was pulled up over the sides and stapled down to the plywood. It was then carried aboard and test for fit. The fit was good so we rolled out the vinyl and repeated the process.

The backrest was done in a similar manner but we used two inch medium density foam to start with. We ran the edges through the band-saw with the table set at a forty-five degree angle to give a nice bevel on all sides. Quarter inch foam was glued onto the face of the cushion keeping it back two inches from the  sides. This helped form the gentle radius shape. Then the half inch thick foam was laid out and the cushion was finished in the same manner as the bunk cushion. The finished back-rest was secured to the settee with strips of Velcro.

Jessie and I started in the afternoon and was later joined by Jared and Kyle. Once we got started we wouldn't stop! We all wanted to see the end results before calling it a night.

As the evening wore on Jared broke away from the production line to whip us up a fantastic meal. Hes an amazing cook and before too long he laid out a feast of tempura yams and zucchini complete with dipping sauce, and chicken katsu served on a bed of rice with a lovely lemongrass, coconut curry sauce over it.

The feat was impressive considering he did it all on a one burner hotplate and a small deep fryer.

After the meal we completed the job and installed the cushions. They fit well and everyone had big smiles as we congratulated one another......it was two am, and a major milestone was behind us!

Thank you guys! Thank you very, very, much! It was a tremendous success and a wonderful evening.

Bunk Foam

I had originally designed the settees so that they would fit a standard futon width and the port settee would fit a standard length also. This would have saved considerable time and money by simply buying a futon and dropping it in place.  The major disadvantage would be dealing with one very large "cushion" that would be difficult to gain access behind and below it.

We have been doing several large vessel interior refits at the shop lately and the crew has become proficient at wrapping panels and dealing with headliner, carpet, and foams, so I decided to go ahead and build the cushions in house rather than taking the easier futon route.

We bought some medium flex high density foam and set to templating the settee bunks.

We stacked 2x4's two high to simulate the thickness of the foam. This allowed for the angled seat-back and ensured the top of the foam would not be too narrow due to the angle.

We used the wood strips and hot glue gun method and made a template in the usual way then took it below and laid it on the foam and drew it out with a felt pen. An electric knife was purchased from the local Wal-mart kitchen center and was used to cut the foam.....it goes through the foam like a hot knife through butter!

The 13 degree seat back angle was cut "free style" by holding the knife at an angle and following the line we drew. It worked ok but I might make a jig for the angles on the rest of the cushions to get a more accurate cut.

Trim

Lately we have been making trim and installing it in the boat. Its a very rewarding job and I have an ear to ear grin after each piece goes in as we stand back and admire our handy-work.

We made most of the trim out of Jatoba (Brazilian cherry) milling down the twenty foot long by six inch planks we bought over a year ago for this purpose. The wood is very dense and brutal on our tools. It dulls saw blades and smooths out sand paper very quickly compared to teak or mahogany. When using the router table to shape the pieces it would go along just fine and then randomly catch the grain just right and throw a chunk out of the piece on occasion. The Tech would utter a few colorful metaphors and start all over again, saving what he could in the hope it could be used elsewhere. It didn't seem to matter what depth or what shape of bit was used, or if it was new or old, every now and then it would throw a chip out and we got used to the fact.

Sometimes it enabled us to get creative as with the vertical trim going into the head....it threw a chip on the last run through after the piece had been milled and almost completely formed. We didn't want to start over so we cut a forty-five degree bevel along the one side of the face where the chip was. In the end we all liked it better than the original, it made the profile on the face look a little narrower and it balanced visually with the piece on the other side of the door frame.

When we milled the boards down we typically used the table saw to get the rough dimensions and then ran the boards though the thickness planer. After that it was shaped using the table saw and router table and then sanded starting with 80 grit and working up to 600 grit. All the pieces have soft corners with varying degrees of raduis on them. The radius had to be hand sanded and we quickly learned to wear gloves as the wood had fine splinters that were needle sharp that would cause a nasty sliver to the bare hand. Once the finish was applied the grain toughened right up and by the time we got six or seven coats on and the final 600 grit sanding done it was like polishing glass. The look was worth the hard work to get there!

Interior

The interior is coming together nicely and its been very rewarding to move off of sanding and sanding, and more sanding .........and move on to installing things. Over the last three years I have been purchasing items for the the boat and putting them in storage so I would have them on hand when it came time to install them.

Its been like Christmas morning every day as we open a box and pull some treasure out of storage and turn it over in hand, admiring it before carrying it up the ladder and into the boat to be installed. The electrical distribution panel was carried aboard, as was several plumbing parts and fixtures. The solar panel and wind generator was placed gently to one side, its not your time yet. The light fixtures and deck cowls were placed in line, soon to be carried aboard. The box containing the shortwave radio receiver and plotting tools, binoculars, etc. were carried up the ladder and placed about the area for the chart table to see how they'd fit.

The top for the chart table was then templated and cut out of half inch plywood. A five inch shelf was left along the bulkhead aft and outboard under the distribution panel to accommodate the shortwave, binoculars,etc.

A thin sheet of cork with self adhesive backing was laid down over the area. I went to the local sportsman outfitters looking for some cork sealer that is used by fishing rod builders but none carried it in stock. I remembered reading on-line that some of the rod builders also used "Tru-oil", the brand name of a product that is used to finish gun stocks. I found a bottle and purchased it but was very skeptical......I didn't care for oil finishes in the boat as they tend to pick up dust and dirt and our shop is on one very dusty road. I applied several coats to a scrap piece of cork and was impressed with the results. It hardened up to a tough shiny surface like an old fashioned shellac. I used it on the cork and it turned out just right, a hard shiny surface that still had some flexible properties to it that other users promised  would not crack or shrink over time.

Plumbing

The plumbing is moving right along. I tee'd off of the head intake pump and ran a line forward into the anchor locker for a deck wash-down and ran a line to the head sink for a seawater tap. There is no discharge anywhere near the intake thru-hull to contaminate the water. The toilet discharges into the holding tank and then the holding tank will have a discharge thu-hull and deck suction fitting aft near the cockpit.

The fresh water tank is located under the V-berth and I needed to vent it but did not want the vent outside the vessel and possibly contaminated with salt water etc. I ran the vent to the head sink and plumbed it into a brass spigot at the sink, that way its inside the boat and if the tank is overfilled the overflow goes harmlessly down the sink. We installed a whale foot pump for the head sink. We could not reach the lower fastener on the foot pump to install it so we cut a thin piece of aluminum and mounted it to that and then fastened the aluminum into place. 

We plumbed it to a chrome plated spigot at the head sink.

V - Berth

The V-berth is coming along nicely.

We cut Jatoba planks and used a thickness planer to clean them up and get them to a uniform size.

They were sanded up to 320 grit disks then several coats of Poly Wipe was applied, sanding with 600 grit every three coats thereafter. We have all but the little pieces installed now. They were screwed into place without any compound so that they can be easily removed to access the wiring and plumbing behind when required.

A fresh coat of paint was applied to the berth and the hatches were installed.