Damaged cabin sole

[wes]

 Just brute force! I pried up one end and lifted hard. It let go surprisingly easily. After 29 years the epoxy was brittle, and the bottom layer of the plywood has delaminated in spots.

But be prepared for a long afternoon with a broad, sharp chisel getting all those globs of epoxy off.

For some reason the perimeter of the sole had not been bedded in sealant. Surprised the factory didn't do this, since it allowed water spills in the cabin to get under the sole. Curious whether they changed this in later years too. On the other hand it simplified the removal. Probably the first time a boat project hasn't included battling 3M 5200 .

Wes

[deisher6]

Wes, as always appreciative of your C-27 blogging. 

Have you considered roughly sanding down the existing epoxy points and using them to support the new sole?

I noticed the cushions and the clean deck inside, boat is  looking up!

regards charlie

[wes]

Charlie - my new sole material is 1/2" thick, but the original turned out to be 5/8". Scraping off the epoxy gives me a chance to shim it more precisely.

I've cut out the new sole and coated the bottom with two coats of epoxy resin to waterproof it. After it cures I'll start shimming. More photos to come!

Wes

[rbh1515]

Here is what I think is the best option.  I had the entire cabin sole done:  plasteek.
Chech it out.  It will last forever.
Rob

[wes]

Rob - the Plasteak product is interesting but it looks like it is only 1/8" thick - so it would need some kind of underlayment below, to build up the 5/8" thickness needed. What did you use for that?

Here's a photo of my new sole. I bought 1/2" teak and holly plywood from World Panel Products in Windsor NC (they have a Florida location too). They will let you pick your sheet from the warehouse. The variation in color and grain from sheet to sheet it huge.

Used the old sole as a template to shape the corners with a router and flush trimming bit, but it looks like the corner radius is 2" fyi. Used a 45 degree chamfer bit on the bottom edge.

I coated the bottom with two layers of epoxy resin for waterproofing. Top is finished with Epifanes Woodfinish Matte - I'll probably put on a total of six coats with the first two being thinned for penetration.

Haven't ventured to recreate the removable access port in the smaller aft section of the sole (where the bilge pump is). Not confident enough of my woodworking skills!

Wes

[deisher6]

Wow Wes! Good looking job as always. 

Is the aft section stable enough that you could use the whole section as an access port?  Mine is held down with 4 screws and I find myself taking it off a couple of times a year.  It would be handy to be able remove the whole thing easily.

Again good work and thanks for the pictures.

regards charlie

[wes]

Charlie - here's what my original aft sole looks like, with removable access hatch. Sounds like yours doesn't have this? Maybe they added it between 86 and 88. Seems like a very handy feature, to quickly check for water in the bilge. But it will stretch my woodworking capabilities to replicate it.

Wes

[deisher6]

Hey Wes, Windrunner has the same set up with the easily removable access hatch.  I was just wondering if it is worth the effort.  It is pretty handy to take the whole aft deck off to clean up the bilge.  However I recently gained some experience with making and installing some bow tie 'dutchmen' to stop the checking in an old dresser.  It should not be to risky to cut out the hatch with a jig.  Mistakes could be covered up by using wider trim around the removable hatch.

Are you going to be at McCotters this weekend? Thinking about sailing up that way later today.

regards charlie

[wes]

Charlie - yep, I'll be at the boatyard from Friday midday to Sunday morning. Planning to permanently install the forward section of the sole and continue with interior varnishing and electrical work. Hope to see you!

Wes

[brackish]

Haven't ventured to recreate the removable access port in the smaller aft section of the sole (where the bilge pump is). Not confident enough of my woodworking skills

Are you kidding me?!  I have serious woodworking skills and I'm looking at what you have already done and it is outstanding.  So the next step is no step for a stepper. Is there room for a lip around the main deck where the removable panels go.  If so I would make the whole panel easily removable.  I think simpler access, less complicated.