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Working on Companionway, Cockpit sides and back, Deck ply inserts. May/June 1992.

3/5/92

Yesterday went out shopping for more fiber glassing materials. We were pondering still over how to solve the steps problem. Eventually decided on a box step, with a pullout step from within. This step can be pushed in, out of the way when not used. Saves space and gives more room to man oeuvre plus added workspace. Note the Engine Cupboard and Step Box are just a mock up made out of softwood and chipboard. Improvements are still to be made and,  later on in the project, it will be made out of Mahogany. 

Mock up Step Box

showing how the Step Box extends

Cut, Planed and fixed a thin wedge to fit on top of the hatch step base, and also the same on the sides. Made out of Iroko. Cut the grass again.

Iroko framing

Iroko Framing

10/5/92

Made up two timbers to fix onto the bridge deck/cabin sides, for fixing down the ply deck at the outer edges. Cut and fixed down the ply on the bridge deck. Cut, planed and fixed a batten along the cabin edge of the bridge deck, on top of which will sit the outer hatch frame. Provides additional seal for the bridge deck plywood.

Shaping bridge deck timbers

fitting bridge deck timbers

fitted ply on the bridge deck

Cut, planed and fitted the outer door frame made out of Iroko. Contemplated drilling through the base of this frame, so that any water which ran down the hatch boards when fitted, would be able to drain away from the base of the hatch frame.

Outer Drop Board Frame

Cut, planed two long beams, to which the cockpit sides will be fixed.  Routered a groove in all the relevant deck beams to accommodate these two extra beams. Had to use chisel where the Router would not go. The Router came in extremely useful.

marking position of cockpit side beams

routering rebates for the beam portside

completed all rebates for beams. They form half of the cross half lap joints.

Yesterday spent time driving around trying to find a place that sold cabinet scrapers. Amidst pouring rain - found some in a small hardware shop.

23/5/92

Cut and shaped the cockpit sides. Stood the cockpit sides on deck and marked up where the Beams where, and then cut the cockpit sides so they sat over the Beams. Thought was needed then as to how we could do the joint where the cabin sides meet the cockpit sides. The Cabin sides are at an angle, and the cockpit sides are straight. Pictures below show the angle involved.  It was a headache. In the end decided upon using the thickest Mahogany we had, and made a wedge with the outer edges rounded. The end product was looking very eye-catching indeed. Planed down the cockpit sides to nearly the finished height - sloping aft.

Cockpit side beams in place

marking up portside Cockpit Side for rebates

finishing touches to portside Cockpit Side

Puzzle - Starboard Cockpit Side meeting Cabin Side

wedged shaped timber solution shown on Portside

30/5/92

Cut, planed and fitted the cockpit back. Shaping it to accommodate the tiller movement, using a hardboard pattern as a template. This cockpit back took time to plane, as it was too wide to put through the electric planer/thicknesser.

making pattern of Cockpit back

Cockpit back being shaped

finished cockpit back

Cut, and collected up the grass to make a bonfire.

6/6/92

Woke Saturday morning, down at the Hull,  to discover we had a rear offside tyre puncture in the van. Most of Saturday spent searching for two new tyres at a reasonable price. One other tyre had surface splits, and with a MOT coming up - we could take no chances on our lives driving the mileage we are at the moment doing the Hull project.

The aft ends of cabin sides were cut to shape as per the wedge and cockpit sides. Peppy was becoming very confident walking around on deck, straddling across beams.

shaping ends of portside Cabin Side

shaped end of portside Cabin Side

"I'm OK. I won't fall"

Saturday night we had a run out to a Marina for evening meal. It gave us both a moral boost to see a Marina of Yachts etc. Not one looked anything like ours will be and hardly any wooden ones at all. Wait while ours is ready. It will be a showpiece.

13/6/92

Very hot today. After charging up the battery, got some more petrol and put mower back together after cleaning the blades, cut the grass. It is quite an old Tractor, and only the other week the choke cable had corroded, and the belt went. We are getting on top of it now. It's not so long each time. Contemplated on where to start on the boat.

14/6/92

Concentrating on 'Portside' cockpit outer deck edging beam. The cockpit sides are sandwiched between this beam, and the other beam fitted earlier.  This extra beam will also allow us to inset plywood inserts into the deck beam spaces, as will be shown further on. Planed, cut and Routered out the joints ( to the existing deck beams) & fitted the deck edging beam into place. 

routering grooves in portside outer deck edging beam

fitting portside outer deck edging beam

cockpit side and deck edging beam in place portside

20/6/92

Routered out rebates in portside cockpit deck area into, which fits the deck strengthening inserts of 12mm ply. All this Routering had to be completed before the cockpit sides were fixed in permanently.

routering rebates for deck ply inserts

routering rebates for deck ply inserts

making and fitting deck ply inserts

21/6/92

Continued with cutting out and fitting plywood strengthening deck inserts. 

28/6/92

Routered rebates, and cut & fitted remaining plywood inserts on portside of aft deck area.

making and fitting more deck ply inserts

and more deck ply inserts

"Where is my chisel ?"

29/6/92

Routered out & fitted starboard side cockpit outer deck edging beam. Routered out rebates in starboard `cockpit deck area, into which fits the deck strengthening inserts of 12mm ply. Routered out the areas for the three cockpit area hatches ready for the teak frames (yet to be made up).  Peppy liked investigating the work done, especially in the after locker now.   

chiseling starboard outer deck edging beam. The joints are called cross half lap.

routering rebates for outer deck edging beam starboard

" What's next ?"

                    

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