In the wake of non-hurricane Sandy

I wasted a few minutes yesterday trying to understand an explanation of why the remarkable storm that hit us earlier this week was neither a hurricane nor a tropical storm, but as with so many things that are not tangible, my eyes began to glaze over.  Suffice it to say, 48 hours of high wind and heavy rain kept me from making my usual forays to the garage to work on the boat.  I could have done it, but I would have gotten wet.  Coupled with a week long drive through New York state to see the changing leaves and visit some touristy places the prior week, I really have not moved along too much on the project.  Fortunately, the storm left us pretty much intact, with minimal damage to trees, and no loss of electricity.  We were much luckier than many people.

I do have some progress to report, however.  The storm allowed me to work on the cabin sides in the comfort of my basement workshop.  I even cut out the two oval portholes, mahogany rims for them, and 1/4 inch Plexiglas inserts.

Cabin sides with porthole parts

The cabin sides, like all the other plywood, has two coats of epoxy.  For the portholes, I made a template the size of the opening, traced its outline on the cabin side panels, and cut it out with a jigsaw.  I then used a rabbeting router bit to remove a 1/4 inch deep and 1/4 inch wide rabbet on the outside surface to accept the Plexiglas inserts.  I cut them out using the pattern with 1/4 inch extra scribed onto the outside.  The mahogany rims were the trickiest.  I cut them out of a 7 1/2 inch by 17 inch board, 1 1/2 inch thick using the pattern for the inside, and using a compass to add an inch to the diameter all the way around.  I cut out the inside with the jigsaw, and the outside with the bandsaw, then used the tablesaw VERY carefully, to resaw into two 3/4 inch thick rims.  Rounded over on inner and outer edge at the router table, and the rims are good to go.

I also finished applying dynel to the aft and side decks.  It went very well.  It was much easier than trying to fit the dynel into the convolutions on the bottom a year or so ago.  

Dynel on aft and side deck

The installation of the cabin sides presented a bit of a logistical challenge.  I finally decided to first attach the molding strips onto the side deck carlins, with 1 inch extending above the level of the side deck.

Mahogany side deck moulding glued to carlin

Then, I took the plywood cabin side panels and bent them around the molding, clamping to the bulkhead at station 6 and across the boat at the forward edge.  I clamped vertically to hold the cabin sides in position on the deck and against the molding.

Cabin side glued and clamped, looking aft.

Starboard side with cabin side clamped in place

I am ready to glue in the cockpit side panels/seat backs, but decided to wait until my water tank arrives because I might want to locate it behind one of the panels.  I ordered an 11 gallon tank, and it will fit easily in the space or, alternatively, below the galley. It is a special order, and I have been waiting about a month for it.  The panels are waiting patiently for their installation.  I am waiting as well but not so patiently.

Cockpit side/seatback panels await installation.

Sometimes, the simplest things get complicated.  I took my centerboard template to a local steel plate fabrication shop that specializes in oxy-fuel cutting plate.  Unfortunately, the technology has evolved to such an extent that the equipment is no longer able to cut from the outline traced from a full size pattern.  It must have a CAD drawing.  (HAL: "Sorry Dave, I cannot do that.") I am now looking for a shop with old fashioned cutting equipment, or else I will need to get the board cut freehand with an oxy-acetylene torch, and spend the winter grinding it smooth.  Oh well, if boat building were easy everyone would be doing it.