| Bolero
Project |
Thursday, July 17, 2008 First and foremost on the day's agenda was the companionway trim. I began with some risers for the sliding hatch runners, which I built from 1" tall mahogany and beveled on the bottom edge to match the coach roof camber. With a hatch opening of about 20", I allowed for enough length for maximum travel, plus a few extra inches to terminate the risers, for a total length of 44". I temporarily installed the risers on the coachroof with bronze screws, taking pains to properly align the two pieces for consistent width from aft to forward. Later, I'd build and install aluminum runners on top of the risers, but for now I needed the risers only temporarily in place so I could proceed with the other companionway hatch trim. |
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The companionway hatch trim comprised 9 separate mahogany pieces, each of which built upon the last in some way, shape, or form. For test-fit purposes, I installed all trim pieces in rough form, without any cleanup or sanding. I began with interior and exterior apron trim across the bottom of the rough opening, followed by a stool, which I beveled at 5° to shed water and ran out 1" beyond the maximum width of the exterior side trim, which I cut and installed next (leaving the top to run wild for later marking and cutting), followed by similar trim pieces on the interior. |
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Finally, I milled 13/16" wide grooves in some mahogany stock for the companionway edges, to retain the swashboards; I aligned the forward edge of the groove with the raised lip I'd left on the stool. I clamped these in place so I could mark their proper height. |
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With all the companionway trim pieces cut and fit, I masked off around the edges--partly for later re-alignment purposes, and partly so the tape would be in place when I installed the pieces permanently with sealant later--and removed all the pieces to the bench for final trimming as needed, edge detailing, and sanding. Once I'd sanded all the pieces through 220 grit, I cleaned them up and applied a sealer coat of varnish, leaving it to cure overnight. |
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I removed all the temporary screws from the cabin edge trim from yesterday, and bored out the holes to accommodate 3/8" mahogany plugs, which I glued in place and left to cure before trimming. |
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After cleaning up the day's detritus, I finished up with more varnish on the old tiller, after hatch, and cockpit seats. |
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