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Wednesday, June 4, 2003
Removing the deck was
something that I had obviously been anticipating since the onset of the
project. When and how were questions that were somehow unimportant
throughout--I knew that, eventually, the day would come when the deck
would come off. But I didn't realize it would end up being quite so
spur-of-the-moment! On
Tuesday evening, I had emailed Nathan, a friend and fellow Triton
owner who had indicated he was interested in helping with the deck
removal. I was feeling close to being ready, and wanted to see what
his schedule was like so I could try to plan a day. Neither of us
was particularly interested in wasting any good sailing days, but at the
same time it was necessary that the weather be at least dry, so that the
electric tools used wouldn't be a problem. I figured we would try to
get it done within a week or so. Wednesday
morning, I headed out to work early, still with no clear indications of
when we might get together to cut the deck off. A few possibilities
had been tossed around for consideration, but we hadn't firmly settled on
anything. When I got home in the late morning, I found a series of
emails from Nathan awaiting, the general gist of which were that he had
ended up unexpectedly free for the afternoon, and was gung-ho to come over
and get to work. So,
just like that, deck-removal day arrived! While on some level I was
prepared, it was still a quick decision, and after confirming, I scrambled
to get things ready for the afternoon ahead. I
wasn't overly concerned about the shape of the hull changing when the deck
was removed, but I wanted to take some precautions nonetheless. To
that end, I had left some of the original bulkheads at least partially
installed, to help ensure the hull would maintain its proper shape till I
could decide on locations for new bulkheads as needed. But in addition,
all along, I had envisioned installing athwartships bracing in a few
places to ensure that the gunwale wouldn't have any tendency to bend
inwards. With deck removal only a couple hours away, I now had to
install these braces. With
most of the main bulkhead (the one beneath the mast step) still in place
and tabbed to the hull, it was a simple matter to install a 2x4 brace
across the top to prevent any inward flexing. Using great care and
finesse, I (ahem) nailed the 2x4 to the bulkhead. (The
bulkhead is obviously slated for complete removal later.) Brace #1
was complete. Next, I
moved on to the most important brace, which I intended to install at about
maximum beam. this corresponded roughly to the forward edge of the
aftermost port in the main cabin. With a reciprocating saw, I cut
slots through the lower part of the cabin trunk and through the sidedecks
to the toerail on each side, essentially removing a 6" slice of the
deck on each side. These slots were designed to expose the gunwale
and top of the hull so that I could install the brace through the
area. It was easy to cut through the decks, and I widened a small
area at the toerail so that I could then turn the saw sideways to cut
carefully along the natural hull-deck seam, thus freeing the deck
section. A surprising amount of fiberglass tabbing was inside the
toerail securing the hull and deck together, as seen in the second
picture. |
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After repeating this
process on the other side, I used a small grinder to remove the paint
inside and outside the hull in way of each cutout. To ensure that my
cross beam would remain in place, I planned to temporarily fiberglass them
in place, and I wanted to ensure a decent bond.
Next, I took two 10' 2x4s
left over from Glissando's project shed and spiked them together to form a
4" thick (OK, OK...more like a true 3", I know) beam. I
laid this across the hull through the slots and marked the thickness of
the hull on each edge. Then, with a circular saw, I cut out notches through
about half the thickness of the beam, to allow it to set over the top of
the hull, therefore securing it nicely in place. Then, I ground the
wood clean and slightly rounded the top edge, and fiberglassed each end in
place with two layers of cloth and polyester resin. Yes,
polyester--this is temporary only, and the tabbing is only in place to
ensure that the beam cannot pop out accidentally. I mixed the resin
nice and hot, so it cured in only a few minutes. By this time,
Nathan had arrived, so I had finished my prep work in the nick of time. |
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With two cross beams in
place, more or less dividing the boat into thirds, I deemed it to be
sufficient for now, and we began preparations for cutting. With two
of us on hand, it seemed reasonable that the cabin trunk could be removed
in one piece. Either way, it was obvious that the cabin trunk was
the first thing that had to go. There was little else to do except
make the cut, so from some hastily-erected staging I went to work with the
say, cutting roughly along the line between the cabin trunk and
sidedecks. We cut all the way from the cockpit to nearly the
centerline of the foredeck, leaving only an inch or two connected for now,
just to hold things in place till we were ready.
Soon, all the cuts were
made, and with a modicum of trepidation I sawed through the last remaining
bits. It turned out to be anticlimactic, since the cabin trunk didn't
crash through the hole created; the slightly raised edges held in nicely
in place till we were ready to actually lift it out of the way. |
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The entire cabin trunk was
surprisingly light, and we were easily able to move the forward portion up
and over to the side. Then, from underneath, I could lift and slide
the after end high enough to rest on the sidedeck. From this point,
we slid it slowly over the edge and then, in one fell swoop, let it crash
to the ground beneath, where it landed upside down. |
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With the cabin trunk off,
the boat immediately took on a sleek appearance from the ground, as you
could now not see the decks from that angle. It was amazing to see
the boat like this, with the cabin trunk gone and sitting strangely on the
ground beside the boat. With a simple cut, that took all of 10
minutes to complete (including "out-loud thinking" time), it
seemed as if we were well on our way to having the whole deck off.
But surprisingly, the rest of the deck removal was more difficult, and
more time consuming. |
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