Friday
In a short work session, I lightly sanded the new fiberglass on the cockpit box and, after cleanup, applied the first of a few rounds of epoxy fairing compound over the sides.
Total time billed on this job today: .5 hours
0600 Weather Observation: 21°, cloudy. Forecast for the day: Another anemic excuse for a snow event, cloudy with a chance of light snow and little accumulation, 29°
Friday
In the cabin, I lightly sanded all the fresh primer to prepare for finish coats. This was a light scuffing by hand to remove the “grain” that the primer raised and to provide a generally smooth surface free from burrs and fiberglass texture. After sanding everything, I vacuumed and solvent-washed the entire area, leaving it ready for the next coat of paint.
This took all morning, and there wasn’t enough time to think about starting the paint after lunch, so instead I turned to the generator storage locker once more, starting by removing the fiberglass tab that had been in the way at the base of the existing compartment.
Next, I marked a new cut line on the aft side of the opening 3/8″ aft of the existing cut to provide ample room for the new hatch coaming, then cut the new line with a jig saw. Then, I cut the pieces of pre-made hatch coaming to length to fit tightly within the opening, overlapping the edges as planned. This was all fine, but the deck here actually had more camber than I expected–it looked and seemed flat or even sagging in the middle–which meant that the rabbetted area of the coamings didn’t work quite as intended, but nonetheless the pieces would still work fine, and where the rabbet ended up exposed at the sides of the opening I could make up with a fillet during final installation.
I’d originally planned to install the coaming pieces piece-by-piece in the opening, but as I dry fit it seemed to make more sense to temporarily glue the four sections together in the right orientation with some scrap wood hot-glued across each corner, after which I removed the whole assembly to the bench and finalized the connections with epoxy fillets at the corners.
The leftover bit of the original glassed-over plywood stiffeners exposed in the new opening on deck needed a little attention now also, as these had long ago debonded from their skins, so I filled the voids as necessary with some of the epoxy leftover from gluing the frame, clamped as needed, and coated the exposed plywood with more epoxy to seal it and prepare the opening for the coaming’s final installation soon.
In final works for the day, I carefully sanded the eight filled bolt holes in the transom to prepare them for the next steps. Also, new bronze flat bar stock I’d ordered for the chainplates arrived; the owner and I had decided it made sense to replace the original chainplates after I found a reasonably-priced source for the raw silicon bronze. The new stock was 3/16″ thick compared to the 1/8″ thick originals.
I’d still have to cut to size and shape and drill the holes in each chainplate, but because these were bronze it was something I could do easily enough at the shop.
Total time billed on this job today: 5 hours
0600 Weather Observation: 21°, cloudy. Forecast for the day: Another anemic excuse for a snow event, cloudy with a chance of light snow with little accumulation, 29°
Thursday
With a new supply of fiberglass cloth on hand, I cut and installed new fiberglass to sheathe the field areas of the box inside of the tabbed corners.
Total time billed on this job today: 1 hours
0600 Weather Observation: 12°, clear. Forecast for the day: Partly sunny, 28°
Thursday
Before starting the primer in the cabin, I had to mask off several areas for protection, including some naturally-finished beams in the forward cabin and head, and the main bulkhead in the saloon.
With that complete, I got started on the primer, beginning in the forward cabin. I found that the cleats within the locker openings were still filthy with dust and debris in the corners, so for now I left those unpainted.
Continuing my way aft, I painted the head. This space, already small, became that much tighter with every brush and roller stroke as I willed myself not to bump into any of the freshly-coated surfaces.
During the afternoon, I finished up in the main cabin, painting every surface except the cabin sole, which would get more of the light gray Bilgekote sometime later in the process. In painting all areas of the empty main cabin now, it was understood that there would later be cause to remove some of the paint to allow for new interior installation and tabbing, but given the nature of the project, with limited time and an extensive work list, too many overlapping and required jobs and new installations hinged upon having the painting done before work could continue, and we didn’t have the luxury of an open-ended timeframe to let each thing flow more naturally together.
Down on a bench, I primed all sides of the various berth locker lids that I’d removed for the purpose.
Total time billed on this job today: 6 hours
0600 Weather Observation: 12°, clear. Forecast for the day: Partly sunny, 28°
Wednesday
For the bilge and utility locker spaces, the owner requested a lighter version of the usual gray bilge paint, so I mixed up a 50/50 mix using a gallon each of white and gray to considerably lighten the color. With the paint mixed, I got to work on beginning the interior paint, starting at the bow in the chainlocker.
Continuing aft, I painted the lockers beneath the V-berth, and around the water tank to the extent possible, before painting the first section of bilge on my way out.
Next, I painted the storage lockers on both sides of the head compartment, and the bilge there as well.
In the main cabin, I painted what I could reach through the various locker openings in the tops and sides of the settees, and the bilges.
Starting with the space beneath the cockpit on the centerline, as far aft as I could reach, I painted everything below cockpit level and through the engine room, including the forward face of the cockpit well.
To finish up for now, I painted the hull inside the port and starboard cockpit lockers, from just forward of the lazarette up to and including the aft-facing sides of the engine room bulkhead. The lazarette still had some work to go, so I held off painting in there for now.
During the afternoon, I turned my attention to that very lazarette as I continued work on the storage arrangements for the small generator. After various test-fits and puzzling things out, I started working on a support platform for the generator that could accommodate it without raising headroom too much. Beginning with the cardboard template I’d made of the generator footprint, after some adjustments for hull shape I transitioned to a template made from some scrap 1/4″ plywood. The new platform would require an angled installation, and the forward end would ultimately be supported against the back side of the cockpit well, but at the moment there was a fiberglass arrangement there in the way (though it did sort of help support my platform templates for now), and I couldn’t remove the fiberglass because I didn’t want to disturb the nearby fresh locker paint, so I worked around it.
Various reference marks I made on the hull and cockpit, along with side views courtesy of the camera held through the cockpit locker openings, helped me start to figure out how the platform would need to work. In these photos, the template is still too low at the cockpit end, but once I could start doing dirty work in the space I could and would made adjustments there and add the requisite supports to hold the platform more where it needed to be to support the generator. In this orientation, the handle at the top of the generator was just flush with the deck above, which meant that it would be clear beneath the new hatch once built. Other details, like chocks, fiddles, and means of securing the generator, would easily work themselves out once the basic platform idea came together.
Eventually happy with my plywood template, I used it to cut a real floor from some marine plywood. I beveled the aft edge severely to help it fit against the shape of the hull and counter at the aft end. I had time to test-fit the platform, but I had one more thing I wanted to do before the end of the day, so that was all for the generator at the moment.
There was a series of holes in the transom leftover from a long-ago outboard bracket, and now I made preparations to fill them. After reaming them out with a large countersink from outside, I cleaned everything up and masked inside and out before filling the holes with epoxy fairing compound. I removed the exterior tape once the fill was in place. With some delicate finish work once the epoxy cured, I’d be able to touch up the paint with something close to the paint that was on the hull.
With the remains of the fairing compound, I troweled over that little line in the middle of the aft cockpit patch.
Total time billed on this job today: 7 hours
0600 Weather Observation: 16°, clear. Forecast for the day: Sunny, 24°
Monday
In a short work session, I finish-sanded the main deck box, smoothing the light 4th coat of fairing filler and pretty much completing the exterior prep work for this box. There’d be additional worn ahead to prepare the interior, to install “feet” on the bottom that would support the box on deck, and to build a lid, before getting to priming and painting.
Meanwhile, I lightly sanded the tabbing on the new cockpit box, smoothing rough edges and preparing it for future steps.
Total time billed on this job today: .5 hours
0600 Weather Observation: 15°, clear. Forecast for the day: Becoming cloudy, snow at night, 30°
Tuesday
One item I wanted to finish before I actually got to the painting inside the boat was to install new support cleats in the various cockpit sole openings. Early in the project, I’d removed (and others had self-removed) several of the old cleats, which had been rotten and poorly adhered and downright dangerous.
From scrap lumber–this happened to be teak–I milled new cleats as needed for the various openings. I set these aside for now, as I couldn’t install them till late in the day when I didn’t need to get around inside the boat anymore, but I’d be back to them later.
Meanwhile, in measuring the openings for the cleats needed, I’d noticed a number of the old screws and nails that had secured the original cleats were still hanging down beneath the sole, so I pulled these all out to leave the way clear for the new installations.
In other preparatory work, I prepared a series of fiberglass assemblies that I intended to use for the surround/coaming of the newly-cut lazarette hatch in the poop deck, which would provide access for generator storage. I knew I already had to slightly expand the opening, which I’d made only just wide enough to fit the generator, in order to fit the coamings (which would provide a water dam and also secure the eventual lid), but I still wanted to minimize the width of the opening, so for the coamings I planned a design with a notch or rabbet that would overlap the opening and provide bearing on the deck surface without taking up too much room. From 1/8″ fiberglass sheets on hand, I used three wider strips and three narrower strips to glue up, with epoxy, enough raw material for the coamings. This gave me 1/4″ width on top, but the portion that would be inside the hatch opening would only require 1/8″ on each side, so I wouldn’t have to enlarge the opening much or possibly even at all. There’d be more work on the hatch opening and storage space in the coming days.
I was awaiting a can of paint needed for the first rounds of interior painting–expected later in the day–so now I turned to the final interior preparations, including another round of vacuuming and then solvent-washing the whole interior of the boat from overhead to bilge and stem to stern, other than the lazarette, where there was more work to be done.
Once the main bulkhead, faced in mahogany, was solvent-washed and appropriately evaporated, I applied a thinned coat of varnish to seal the wood.
At the end of the day, with no more work needed inside the boat, I epoxied the new wooden support cleats beneath the cabin sole in the various bilge openings, clamping them tightly and cleaning up the excess epoxy that squeezed out along the cleats. I’d done what I could to prepare the underside of the sole for the epoxy, and used abundant amounts of the thickened mixture to ensure that the cleats would end up well secured.
Total time billed on this job today: 5.5 hours
0600 Weather Observation: 25°, sleet. Forecast for the day: Sleet, snow (yeah, right), maybe some freezing rain, gross, 30°
Monday
The cockpit required (what I hoped was) one final round of major sanding, this time just to square away the two larger patches over the icebox hatch and at the lazarette, and the minor areas at the cockpit well corners that I’d still been working on. Using only a finishing sander and finer paper than during the earlier stages, this work still occupied a fair bit of time, and afterwards, I sanded the entire cockpit–seats, coamings, bulkhead, and well–with 120 grit on the finishing sander to bring the whole area into readiness for high-build primer.
The lazarette hatch patch (natch) still required a small bit of touch-up fairing to take care of a troweling seam in the center, but that was small stuff. The cockpit scupper openings required just a touch more work too, but now I could and would take care of these small chores in between some of the other work I’d planned rather than having the cockpit remain the priority.
After doing some minor sanding work on some small projects unrelated to Lyra, I spent some time cleaning up the boat, mainly the interior, to make it habitable and get ready for the work list ahead. In the immediate future my plans included painting most of the interior, including bilges and lockers, which would get things ready for some of the other critical installations like the propulsion and electrical systems, and some initial interior construction.
Before I could get to the painting prep and painting itself, there were a couple small jobs I should take care of first, starting in the forward cabin, where I had to remove a few leftover pieces of whatnot to clean up the space: A couple eyescrews beneath a shelf, some old fasteners, and some wooden supports that remained behind from some old installation or another. This was hardly a noteworthy project, but part of the process nonetheless. I made short work of it.
During the interior sanding, I’d sanded away the varnish from the port side of the main bulkhead, where some previous owner had installed thin (but wide) mahogany planks over the plywood beneath. But I’d stopped after doing that section, as the old finish was too stubborn to remove efficiently with sanding alone, gumming up sandpaper too quickly, so I’d left the starboard side to be stripped with scraper and heat, which I turned to now. I wanted to finish this before I did any painting so as not to harm new finishes; I planned get a coat or two of varnish on the raw wood to seal and protect it before I painted as well.
The starboard bulkhead was deceptively large, and took some time to strip as the old coating was heavy and gummy and didn’t scrape that cleanly either. I also stripped the trim at the passageway leading to the head, but stopped there, planning to leave the bits of natural woodwork in the head as is because of scope considerations (those areas could be lightly sanded and some new varnish applied later).
Once I’d stripped the old varnish, I sanded both sides of the bulkhead, and all the trims in the area, with a finishing sander and a couple grits of sandpaper to clean up the wood and prepare it for recoating.
This took up the bulk of the afternoon, and I finished up with another light sanding and the 5th coat of varnish on the new forward hatch frame.
Total time billed on this job today: 6.25 hours
0600 Weather Observation: 15°, clear. Forecast for the day: Becoming cloudy, snow at night, 30°
Sunday
With the cockpit box securely glued, I removed the zip ties–most of them slid out, but I cut and abandoned the rest–and then lightly sanded and rounded over all the corners of the box to prepare for fiberglass. Afterwards, I installed tabbing over all the seams, leaving the field areas for another time since I had no appropriate fiberglass on hand at the moment (it was on the way).
Total time billed on this job today: 1.5 hours
0600 Weather Observation: 15°, cloudy. Forecast for the day: Cloudy, 29°
Saturday
Now that the wedges were securely glued in place beneath the new holding tank platform, I removed the clamps and coated the plywood edges and bottom with epoxy. These areas would never be seen once the platform was in place.
Using some guide marks I’d made up in the boat during a tank test-fit earlier, I made a relief cut in the portside divider from the holding tank compartment, which would allow clear passage of the inlet and vent hoses to the tank. I made the opening larger than it had to be because there was no reason not to, but left the bottom edge higher than the top of the tank so it could possibly receive a cleat to help secure the tank, or to support a shelf above. Afterwards, I painted both sides of the divider to prepare it for reinstallation soon.
In addition to the large deck box underway for the coachroof, the owner had also requested one in the cockpit, at the aft end, to hold the spare propane tank and whatever else might fit. I was building these one at a time at the moment because I was juggling two projects at the same time, and now was a good opportunity to begin the next box. (There’d be two additional, smaller boxes for the coachroof to come as well.)
The cockpit in this boat was already small, and with virtually no good storage spaces. The space in which the new box was to fit was at the aft end of the cockpit, which was angled steeply because of the shape of the boat herself. To maximize useful space and make the box fit as well as possible in the cockpit, I planned for it to be angled to fill the available space, and after some measurements started with a cardboard template of the bottom. The new box would be roughly as high as, but not higher than, the adjacent seats on three sides, and the aft end of the box could tuck into the molded recess at the aft end of the cockpit. The small propane tank would fit nicely in the angle at the aft end of the box, and while it would take up the bulk of the room in the box, there’d be space for other small items, and possibly a removable shelf above the tank for additional storage.
Satisfied with the template, I transferred it to some 9mm plywood and cut out the base, along with a slightly larger version that would eventually form the lid for the box (I set that aside for now). Using some plywood as temporary stand-ins for the sides and back, I located the propane tank on the base and marked the circle at the bottom of the tank on the plywood, for later use in attaching some cleats that would help secure the tank within. That was for later.
Then, I made up the four sides of the box. Allowing for 3/8″ high “feet” beneath the box (to keep it clear of the deck), and the 3/8″ (9mm) top of the box, and erring on the short side, the side pieces ended up 15-3/4″ tall, all of which would ultimately fit within the 17″ high maximum space (the height of the nearby seats). I secured the pieces of the box together as I went with small holes through which I tightened zip ties.
Now I test-fit the tank in the box, showing a roughly 4-5″ space above the top of the tank for an additional shelf. Then I checked the fit of the box in the cockpit. The floor space the box used up was not particularly valuable, and in any event the owner had kept the spare tank there in past years, covered with an overturned bucket, so this was only making better and cleaner use of the already spoken-for space.
With the box dry-assembled, I installed epoxy fillets on the insides of the box over all the seams. These would hold the box together and reinforce the joints along with the fiberglass tabbing I’d later install on the outside.
I thought I’d finish up work for the day by permanently installing the fittings in the new holding tank. Of course this ended up being a tougher job than I’d expected, and harder than it had been doing various dry-fits, but I got it done and was happy to have it so. I started by making up the diptube for the discharge, using trial and error to eventually get a length of hose (with bottom cut at an angle) to just about reach the bottom of the tank.
I thought I’d be able to put this hose on the internal hose barb once the main fittings were in place, so I applied 4200 sealant to the bronze discharge fittings and installed them through the tank, only to find that getting the hose on after the fact was impossible thanks to the right fit over the barb and the more-limited-than-you’d-think-it-would-be arm and hand access/dexterity through the inspection port and to the corner of the tank, so I had to remove the threaded barb fitting and put the hose on outside the tank. Then, I couldn’t get the threads started again–once more, a simple task when dry-fitting, but somehow impossible once the sticky stuff was in play and suddenly the whole thing mattered.
So with some mutterings of displeasure, I removed the top fixing nut (covered in goop), then the entire assembly so I could thread on the base fitting with the hose, and install that whole piece (hose, hose barb, and threaded neck) back into the tank. This worked, but it was all messier and more time-consuming than it had to be. I threaded on the bronze tee and tightened it before finalizing the installation so I could ensure it ended up facing the right direction.
With the hard installation out of the way, the remaining two fixtures were much easier to install, also well-bedded in 4200.
After cleaning out the inside of the tank, I saw no reason not to install the inspection port and remaining fittings. Once work on the new platform was complete, I could install the tank and finish up the work on the head system.
Total time billed on this job today: 4.5 hours
0600 Weather Observation: 2°, mainly clear. Forecast for the day: Mostly sunny, 23°.