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Website started 24th February 2000

Making Hatch for a Canal Barge. Boat Yard Hassle. Companionway Hatch finishing touches. September 1995 to May 1996.

18/9/95

Postman knocked this morning. But neither of us heard him. Package was underpaid, and had to be collected from the sorting office. It was the quotation for Teak decking and Plywood and Teak pieces to complete a Hatch we were also making for a canal barge. The envelope had 19p stamp on it, 39p underpaid. What a shock to us when we opened it as well. Not a very good response to the questions we had asked, so we had to re read all the brochures to try  uncover the answers. The quote was all for teak, not teak and mahogany as requested. Anyway for the 3’ x 4’ Barge hatch the total cost of Teak, Mahogany and 12mm + 18m ply would be £302.93 excluding the labour to make it up!. The Barge owner had given us £100 for timber and really did not want it costing much more. What now!. We cannot buy lumber as we have no planer. No one else around here sells teak or mahogany PSE. A real headache it was. We even got the original Barge hatch in again. Could we save by restoring part or most of the original. It turned out two pieces of ply had been used. A cheaper 6/7mm then a 8/9mm exterior ply. Neither of these were worth saving and the frame although in places appeared ok ,the time needed to clean up and remove all paint etc would be unjustified. In any case the front piece should be in one piece not two. The less joints the better. This analysis drew up one conclusion, a totally new Barge Hatch had be made. At 16:00pm sped off to see if we could get some stainless steel welding wire. This had ran out recently and we have not completed the welding for our companionway Hatch. No luck locally. Visited a local Builders merchants and only just managed to find some decent joinery timber for the sides and aft of the Barge hatch frame. Nothing good enough for the 3" x 3" front piece, and the exterior ply was of extremely poor quality, having used top quality marine ply on our boat. It was 17:00pm now anyway. Today completely gone and it had done little is anything to boost our morale.

19/9/95

Visited a local Joinery shop who had no 3" x 3" timber pse softwood, but they did actually stock Iroko. They quoted us for the Iroko, needed for the Barge hatch, which we agreed to go ahead with. It should be ready in a week. Sped off then further afield to find another timber place which deals with Quality Joinery wood pse. Our luck was in and they had a piece of 4" x 4" about 46" in length. We needed 41". That purchased, we then picked up some stainless steel welding wire,  plus some router bits we needed. Penniless and shattered we returned home about 17:30pm. Just settling down to salmon sandwiches and cup of tea and we both gulped when a van pulled up outside – it was Dad and Brother having driven 150 miles to visit us. What a big pleasant surprise. They stayed four days and each night was a late night. We all visited the boat on Thursday, stopping on the way for some Marine ply for the Barge hatch. Brother managed to climb onboard, but Dad was content just to get to the top of the steps. Later Brother just did not want to leave. He was planning on camping out down at the boat, he was so overwhelmed with the sea air, river view and surroundings.

23/9/95

Our surprise visitors left last night, but today we could not concentrate on our boat, having been thinking of nothing much else apart from the Barge hatch recently. Needed to rekindle the thoughts on the Barge hatch. The intricacy and complexity of the hatch was more than initially thinkable – not helped by the cost of the hardwood.

This weekend and the next( as it was raining) spent finishing routering the hatch woodwork , and completing the welding for our hatch. At one point the owner of the Barge visited us at home, and he saw our Yacht hatch on the lounge floor and he dived straight down on the floor and wanted to have his hatch made just like it .!!!

6/10/95

Again weather rain. We have never had so much rain in such a short spell. Sunday we spent down at the Barge as we had a spare set of boat keys, and had a good fitting out session with the hatch. By 13^th the hatch was ready to handover to the owner for painting and then to fit it sometime next week. We had given it a coat of metallic pink primer.

14/10/95

Traveled down to our boat this morning. Had to shift a large trailer out of the way to get the van up to the boat. No easy thing to shift either are trailers. Weather quite pleasant, sunny with cool breeze. Uncovered the boat. The Tarpaulin is on its last leg. Water is now seeping through. Plus the carpets are absorbing water and trapping moisture within. Lifted them all today and dried up any moisture and dirt. Took the hatch up on board. This is the first time we have been down since we took delivery of the metal and completed the welding. Worked out the router slot measurements for the naval brass strip to be seated into the iroko runner pieces. It was about 17:00pm. Lots of dust made and we routered out both iroko runners pieces. Needed 3 or 4 runs with router for each runner. Placed the naval brass runner into the grooves, then slotted the hatch into place. With Ruth holding the naval brass strips forward, Lance slid the hatch up and down ( sorry forward and aft) with ease. It was all coming together extremely well. It was a great feeling of the first working part of the boat nearing completion. It was by now 18:30pm and the temperature dropping rapidly, as was darkness setting in rapidly. Had to quickly tape up all corner carpet pieces, leave the hatch and runners on for tonight, and cover up.

15/10/95

Sunny start to the morning but then clouds formed and threatening rain showers followed. So much for the forecast yesterday of 19degrees. We re-penciled the beam lines on the forward deck area. We cut the aft end of the Iroko runners, shaping them towards forward. The naval brass was then repositioned, and filed to the same angle so the ends sat flush. The aft ends of the iroko runners where cut to length and the naval brass cut to length. By evening the naval brass had been routered along the top outer edges to take the corner off so it runs better in the stainless steel. Tried a hss router bit initially but the naval brass ruined it. Then utilised a countersink bit in the router , it had the same shank size. With care, and making lots of noise, it did the job well. Then the edges were finished off with sandpaper. The aft end of the naval brass runners were rounded off on the outer edge. The forward ends needed doing likewise. Drilled out three holes on each strip of naval brass and screwed in place with 6 of 8x1" stainless steel screws. Having screwed it down though, the hatch was more obstinate to move. Needs further sanding on the stainless steel and naval brass to home the pieces together. It will take time but the practicality of the idea is proving very suitable and workable.

11/11/95

Had a three week break. Finished off the lengths of naval brass for the hatch runners i.e. rounding the ends and edges. Also completed the fitting of the Barge hatch we had been busy with.

Arrived at our Boat about 12:30pm to discover that work had been done where our boat is, and that the yard had tried to move our boat without our knowledge. We had had no phone calls either!.  There was now two new water taps fitted in the hardstanding area, our steps had been dragged from their position, breaking a bottom cross piece, our padlock was missing, although the chain remained. This was securing the steps in place to the cradle. There was a pile of timber rubbish next to our boat where the steps were. The trailer extension trolley, the chap on the motorboat had left with us, had disappeared – maybe – hopefully they had popped down and picked it up. We shifted the pile of timber rubbish, including a 3’ level. We were hoping now that they had only wanted to move our boat to lay the water pipe down easily. We had to position the steps alongside the starboard side, after knocking back into place the cross-piece. The tarpaulin is holding out. By time weather cleared today, it was getting dark.

12/11/95

It was nearly 10:30am before the sun broke through and we felt safe to remove the tarpaulin. Not completely though. Water had collected on the cockpit seating area. We do need to drill a small hole in each corner aft to allow water to escape onto deck. This was done later. Dried off the excess water on board. All was dry inside though. Then screwed into place the naval brass hatch runners, and fitted the hatch. It fitted well, but some further planing was needed on the wood surface exposed uppermost. This was done and also washed down the side deck with warm water and sponge. Spits of rain were teasing us. Should we cover up or not. We hesitated and it blew over. Returned from the Chandlery with more Duck tape and made up fresh carpet protection pads, this time duck tape was put on both sides of the carpet, sandwiching the carpet completely inside duck tape. Just done this when it looked like real rain again. Quickly pulled the sheet back over, and propped it up over the tiller. Makes a temporary measure, but cannot do much except wait for the rain to stop. Twice we had to cover over, until finally we called it a day, the rain was set to stay. We had managed to drill out and screw into place all screws in the naval brass hatch runners. We had to call it a day about 15:00pm. It had not been quite the weekend we had expected. Tied rope around the steps to hold them to the cradle, until we find the padlock !,

25/11/95

Rent due this weekend. Arrived at the boat about 13:00pm to find a row of Melgres24 on trailers across our access to the boat. Fortunately, between us we just managed to push and shove one of the trailers to one side. Weather overcast and showers of rain. Both of us walked over to the harbour office to pay the rent, and request our power be switched on. Then we visited the chandlery to get another replacement padlock to lock up our steps. They had not been moved this week, and chatting to a Yachtie in the boatyard he said it was when they used the digger to lay the the kerb stones, that they had tried to move everyone except us. In between showers, we uncovered the cockpit area, and dried up the deck. Noticed the electric meter had been moved into the hardstanding area next to the water tap. A second meter box was now the other side of the hardstanding. Our electric was nearly forgotten about , and a young yard lad came running over. The 2^nd meter cupboard has got 16amp fuses/trips in them. In turning our electric on though the lad switched off another Yacht. The chap on board was not too amused, and had to call up the Harbour office to get himself switched back on, as by now the yard lad had disappeared. We asked the lad reference the 1/10^th s on the meter reading. He was able to confirm our thoughts. We were being charged 900% over for electric i.e. £10 instead of £1. Not able to do much today. The evening looked pleasant, so went to the bar without coats. However rain came down, and really really heavy too. There was a family with grandparents on the table next to us and they all wanted to get back to the Yacht but they had not got their coats either. After much waiting for the rain to stop, Lance suggested to them about using a black bin liner. Grandad jumped at this idea, got a black bin liner from the Bar staff, put it over his head, poked holes in for his eyes, nose and mouth, and off he ran across the yard and down the pontoons to their Yacht to being back the families coats. The whole bar was in laughter to see him running there and back. We just managed to nip out later in between showers back to the boat. It was pleasant to sit in the van and listen to the rain dropping off the sheet, running down the aft sash cord, and dripping off just above the rudder. 

26/11/95

Weather testing us. Cool wind, but strong. Puffy clouds of all colours passing over, blue sky on occasions, with Sun shining eventually. Bravely took off the tarpaulin.. Minutes later rain spitted, but by the time we had um and arghed it had blown over. Just a quick shower. The after deck is suffering, and we took action to drill two holes aft of the cockpit seating area, one portside and one starboard to allow the water to drain through. All the epoxy exposed to the sunlight has now flaked off. It is not UV protected. Continued with the main hatch runners. The hatch catches around centre and needs gradual sanding down to marry it down We had no vaseline with us, only graphite powder. The yard lads shifted a large motor vessel out of the shed, and were about to put it next to us – almost saying to everyone to move their cars etc, then they changed their minds. They found space further up the yard. But no-one could had checked the boat before moving it, as we later noticed on it was a container with what looked like paint, white spirit & a brush blown over on deck, the contents spilling out onto deck !. Someone was not going to be amused. The day turned out quite pleasant. The sun made all the difference. The ply deck got chance to dry out, and once dry it did not appear too damaged. Will need a good sand down. The tarpaulin is deteriorating but maybe it will last until we get the tabernacle finished. There is now only one other large Yacht in this hardstanding area with us, and the owner has been told that we have got until spring to move out of the area. It is ludicrous really. It is just what we do not need. No matter where you go, or what you do, you are surrounded by hassle. Had a good walk around the yard, to see where else would have been suitable for us. We are really in the best position where we are. Alternatively we would choose behind the shed near the chandlery, simply because it would be unlikely we would get blocked in. Other than that it would need to be in the shed, at a cost. We have in the mean time had no letter regarding such from the Marina. ?. Persevered with the hatch runners, and it is improving slowly. Taped up some more holes in the tarpaulin, replaced eyelets which were tearing out. By 15:00pm the wind was really turning bitter, and the sun was starting to disappear. Time to call it a day, and cover the boat up.

28/12/95

Too cold to work, we gave ourselves a Christmas Break. Rent due today which we paid to the Yard Manager as the offices open. He mentioned re the Hardstanding area is to be let to dinghies only during the summer months, and would it be a problem for us to move?. He will try though to keep us there where we are now, as we won’t be moving for some time. The cover on the boat appears intact, just a small portion of ice in the corners of the aft deck. The holes in the covering board port and starboard aft have been letting the deck water escape. The Boats are arranged better this winter. All around the perimeter, allowing vehicles access better. Cold biting wind though. Just managed a beer in the bar before it shut at 15:00pm. Maintenance being done on the pontoons and 95% of boats are out of the water.

24/4/96

Only been down of recent to pay the rent each month. The boat on each occasion looked ok, cover still in place,. We cannot get up to the boat yet, we are pinned in the corner by other Yachts again. Besides the weather is far too cold. Came down yesterday Saturday. Weather very warm and sunny. Hardly a puff of cloud in site. Could not get up to our boat with the van, too many cars and dinghies . Parked as close as we could and uncovered the boat, but all afternoon we were nagged by the dinghy racers erecting and dismantling their equipment. They take too much to chance, and could easily damage any vehicle parked there. It was unnerving to say the least. Later in the afternoon youths started Kite Flying !!, and one darted , just missing Lance and landed on the deck !!.  We re-pencilled all the deck beam lines on the plywood. Weather elements had erased most of the original markings. The teak oil on the exposed covering boards had totally faded and the epoxy exposed to the utlra-voilet was flaking on forward and aft deck. Need to get the teak down this year. Washed down the hull upper exposed areas, to remove as much dirt as possible, and dried it over with a towel. Sat around for the rest of the day as a yachtie from just up to us, popped up for a long chat. It was 20:00 before we knew it, and dashed off to the bar, only to find a large party had arrived to eat, and no more orders were being taken!. Having not eaten for the last 24hours, we had to make do with lots of Guinness and a dozen packets of crisps. I seem to remember this happening once before to us. We were both plum tuckered out that night and slept well.

24/4/96

Sunday. Not such good start to the day weatherwise. Windy , cold and although sunny – very cloudy. Checked over the underneath of the hull, but could not find any damp timber. Just the carpet covering the cradle. With it being cold and windy , took a while before we got into the swing of anything. Set to working further on fitting the forward cross-section of the companionway hatch. The beam had been prepared last year, but the upper camber could not be completed until the Hatch was completed and fitted. Had to recollect how we had contemplated fitting it etc with reference to the hatch. Before it could be fitted needed to rebate a water channel in the hatch runners from about 1" in from the aft inner edge to the most forward inner edge. This will accommodate any water which does find its way underneath the hatch, and direct it out of both hatch runners. Unfortunately it meant channeling it directly over the hatch runner screw plugs, but only three screw heads showed through. This made lots of sawdust, and we need goggles when working like this outside, because the wind blows sawdust in all directions. Ruth has to hold the electric cable, to facilitate ease of movement for Lance with the router. The forward cross-section beam was channeled out likewise, and then also routered out (20mm) to accommodate a section of naval brass strip , the same as the hatch runners. The idea of the naval brass strip is that we will have one on this beam fixed to coachroof. Then there will be a likewise beam piece and naval brass strip on the underside of the hatch. The latter will be detachable from the hatch forward edge. This should keep the draughts out, and drain water away from entering the boat. This forward section was then clamped in place , and drilled and prepared for 5x 1 ½" screws, slotted self tappers. Need more no 10 Iroko pugs making up. Is it about 14:15pm now, weather still unsettled. Got out all the epoxy gear and used 1 plunge epoxy resin and 1 hardener as a initial coating. Then used 3 plunges each of epoxy mix, with microfibres, to act as a gap filler, as well between this forward hatch opening section and the coachroof. The beam was clamped and screwed into place. All we have survived on up to now is plenty of tea. Will have a big Chinese when we finish tonight. 

Fixing into place the cross beam piece, on top of which a naval brass strip to be seated. On the underside of the hatch will be a similar beam piece fixed with a naval brass strip seated in. When the Hatch is shut, these Naval brass strips will marry up.

3/5/96

During the week a start had been made on the tabernacle. We took time to carefully grind down the back plate of the tabernacle, and then carefully drilled a ¼" pilot hole in the marked up tabernacle sides, using the morse cutter drill bit . Contacted the stainless steel stockist re sizes available for the two pivot bolts. Cannot complete sides any further until we get the bolts. M20 x 150mm are the best available, so ordered 2 x bolts, dome nuts, nuts and 4 washers. Posted letter and cheque tonight. Packed the van and arrived at the boat 22:00pm. Shifted a dinghy out of the way, asked for electric to be switched on, and set ourselves up for a long bank holiday weekend.

4/5/96

Saturday morning. Pleasant warm morning, uncovered the boat and climbed aboard. The ‘Slipway’ security chap also popped up for a quick hello, and how are we getting on. Changes in the Yard means you now have to pay to use the launching slipway, and this chap bombards you for your money. Continued with the hatch area and made up and fitted a short length of naval brass strip across the forward beam epoxied in place last week. Used 5 x (8 x1") s/s screws. Made a start on cleaning up the brass hatch with brasso. We had brought the pillar drill with us this weekend in anticipation of doing the naval brass strip. How to make up the beam section on the underside of the forward hatch end was the next problem. This was to marry up with the naval brass strip just fitted. Taking into account the future clearance of the hatch from the deck once Teak decking in place, this beam piece needs to be removable to facilitate ease of removal of the hatch completely for maintenance.  Contemplated many ideas before settling for a piece of iroko, and made another length of naval brass, bolted to the underside of the hatch. It was about 16:50pm so dashed over to the chandlery emerged with 5 x m6 x 60mm bolts and washers and buts, a tube of marine grade silicon mastic, and a length of vinyl adhesive backed rubber tape. Back to the boat, the hatch was removed, and carefully carried down to the workmate. It needs both of us to carry it down The centre hole of the naval brass strip was screwed into place only, and it was put back on for a fitting, the hatch that is. The naval brass strip was straightening itself, and therefore we decided to drill for and fit all five bolts. So far it is working well. Only worry is that the naval brass strip may force the forward edge of the hatch out of shape. Both the naval brass strip on the underside of the hatch, and the naval brass strip on the deck beam meet, and seat very well. Needs thought now on clearance between the deck with regards to the bolt heads. Cannot narrow the underside iroko strip any because of the positioning of the naval brass strips themselves. May need to chamfer the deck between the hatch runners as the hatch clearance increases forward. The hatch is no light weight, and we had slid it on and off many times today. Not wanting to go without dinner tonight it was too cold to change, so just got out big jumpers and off to the bar. We had to eat what we wanted, but came away plum tuckered out, full up and could hardly walk back to the boat. Decided it does not look like rain, and left the boat uncovered. However stuck some masking tape over the mast step holes just in case of rain.

6/5/96

We were up at about 7:00am and sat on board by 8:00am. The sunrise was pleasant and warm, the river was peaceful. This lasted for an hour or two, then once the tide turned so did the wind, and it stayed unfortunately for the rest of the day. It is most unpleasant working with a cold wind down ones neck. It was very difficult to get stuck into anything big. The starboard cockpit corner piece badly needs starting on, as cracks developing in the end of the main cabin side starboard are traveling inside the main cabin. The three cockpit hatches need doing before the boat can be left uncovered. Thought over options of doing the hatch frames etc. also much thought needed re which timber to use for the best. Ideal to use as much of what we have got, but not to use anything inferior for the finishing touches etc. Poser here to work out the water tightness of the hatches and drainage of cockpit seating etc. It is looking like the best option is to make up a frame, rebated to cover the deck ply, but which will end up flush with the teak decking. Then attempt to make up a spigot of stainless steel, bent and welded at one joint. Looking at the drainage holes at the base of the drop board slots, they looked black, dirty and too small. We wondered initially about using the 15mm domed router bit to router a groove along the bottom frame piece along the path of the drainage holes . This was decided upon and done wearing goggles whilst using the router. And once finished we hoovered up the dust before it had chance to blow away. Having routered out this 15mm channel, it then followed that perhaps the drainage holes should be routered out (plunge routered ) with the same router bit. We did go ahead and plunge router the holes. Wedged the router between two pieces of clamped wood to hold it in place, and routered it so it just plunged through the forward side of the framework. The hole did look big initially. Having now done one hole we had to continue with the rest of the holes. Once done it did not look too bad. In fact it looked quite attractive and professional. It will certainly be easier to clean and if we really wanted, we could utilise 15mm copper pipe to line the holes with.  The ‘slipway’ security chap, has now been instructed to keep the yard clear of vehicles, except where a person is working on their boat. It is in our favour that they are keeping the cars away. The slipway floodlights are now switched on each evening, which makes it better for us. Last night a rubbish bag had been torn apart , around the corner, obviously an animal of some sort. The duck and drake visited us today, and they sat for some time on the bank near the meter box. Air show close by today gave us spectacular sights of spitfires flying over in formations. The sun shone on rare occasions today. The wind was cold and annoying. Did not do much else all afternoon. Both of us feeling peckish, with the cold. Had plenty of tea, coffee and soup to keep us going. Having dug out some iroko lat pieces, it was suggested they would be ideal size for edging the hatch with , to cover the stainless steel runner edges and to chamfer the upper and lower edges. It was by now 17:30pm. We decided to stay until tomorrow as it was Bank Holiday. And out of nowhere came a burst of enthusiasm to get stuck in to a job. Down came the hatch. Used some rubber matting to stand the hatch up, and wedged it into the workmate. The edge was then planed flush with the stainless steel runner, and sanded. Two lengths of iroko battening were cut to length 260mm x 1". They were both chamfered on top and bottom face edges, then using the pillar drill and the 9,5mm flat bit 10 countersunk holes were drilled in each lat. They were to accommodate 10x (8 x 1") stainless steel screws. The holes were drilled in the timber hatch sides and one lat was screwed into place. The whole operation was then repeated the other side, leaving 1" overhand at each end of the lat. The iroko lats had been down under the boat. Put the remaining bundle inside the boat.  By now it was 19:30pm and good time now to clear up and go for eats. The whole yard has been extremely quiet today. Again had a good meal tonight. Not sure which is worse, starving for two days, or eating too much.!. Both slept well tonight. We fell asleep first off on top of the bed fully clothed. Again left the boat uncovered – it did not look like rain.

6/5/96

Awoke at 6;00am this morning and saw another beautiful sunrise. Later whilst having coffee we had a visit from a grey squirrel. We also heard the cuckoo offshore yesterday. We keep dropping the tarpaulin from over the cradle corners whilst we are there , to try and dry out down there. The carpet on the cradle badly needs replacing with something else  ideally waterproof. Wind persisted today, and cold it was. Need to dig out the combing pattern. What a difference it would make it we could have got a spray hood. Another day of ideas, thoughts. For the hatch frontage to we don’t have left any decent wide iroko pieces. Going to need to seriously buy a selection of teak. There was a shorter off cut of Iroko which would do for the forward and aft hatch frontage pieces. However it would need planing and thicknessing. Completed a more comprehensive list of teak and mahogany requirements to complete the hatch, lat out the cockpit sides and cockpit well,  and to floor the cockpit. The cockpit well will be framed but thickness of timber around the perimeter to be tapered down to 13mm. This way water will be encouraged towards the cockpit drains. Hoovered the boat out as well. Also  need to make up a batch of Iroko dowel plugs of 10mm. Taking the hatch home with us to complete further work on it.

10/5/96

Still not having received our two mast tabernacle bolts we rang up. The chap was about to ring us as he was having difficulty locating such. Although they are standard stock, his suppliers had none in and it would take a week before he would receive them. We told him we could wait and to send them on as soon as. The suggestion of today was to visit a Timber Stockists some 35 miles away to see if we could get some off the shelf pieces of Teak/Mahogany to allow us to continue with the hatch etc. We had not yet visited this place. Took off about 13:00pm. Found the Timber place, but what a big disappointment. It was a small shop place, up a one way back street, and all around was either no parking or no spaces left to park. We drove round and round trying to park. Still no spaces, so we asked in the shop, if this was the one and only shop place. It was , and at that moment someone moved off in their car, so we quickly reversed up the one-way hill and filled the gap. The shop was not separated building and marine. It was all one, and the mill/workshop next door did not keep off-shelf pieces of pse timber. All they had was lumber. We looked at the small stock of teak lumber they had. Could not see it very well at all anyway. They work on ordering basis. We bought some alu-Oxide sandpaper strips, and some balcoton glue. We left rather disillusioned with the size of the place. As we said often one is better off not visiting the place. Just order by phone/post. The catalogue certainly gives the idea of a large stockist/mill. Both now depressed. First no bolts, now no timbers, we left for home. By time we got home our minds were working overtime. How can we get this timber, where from etc as it needs to be pse. Out came all the tool catalogues and looking at ideally what we would need. A Snip-off saw, a Radial arm saw, and a planer/thicknesser. Not much change out of £2000. Needs some serious shopping now.

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