Mark 1 cabin refit ...

luigisante · Post by **luigisante** » Mon Oct 17, 2011 12:27 pm

The piece of teak trim from the outside of the Telstar will be a perfect sight-break for the under counter light.

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It looks nice sanded. As an aside, the best piece of equipment I have purchased for this project in a long time is the 60 grit sanding sheel flap-wheel for my Porter cable grinder. It takes off any varnish, etc on this old teak and exposes natural wood in no time.

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You can see how complicated the end trim will be, in order to cover all of these pieces of trim and the fiberglass rail.

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(con't)

Edit: I have posted a short video of the cabinets opening and closing. http://www.youtube.com/watch?v=NLbBcbV28Uo They work really well. The little plastic catch that Tony had in the original boat still works great.

luigisante · Post by **luigisante** » Mon Oct 17, 2011 12:33 pm

I had to literally carve this piece of trim to make it fit on the end.

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It looks fairly good now that it's done.

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I'm going to laminate formica on the plywood top I have and then add an oak veneer on the bottom/front piece. I am already thinking about the steps after the rough construction is complete. I am trying to decide it if I should leave the electrical panel on the port aft side of the cabin or move it to the port cabinets. I am thinking that the port side of the cockpit would be a great place to put an electronic instrument cluster and by moving the electrical panel up to the cabinet over the nav table, I would be moving away a significant source of interference. On the down side, I will have to move all of the wiring.
Here is the space I'm considering using.

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Lou

luigisante · Post by **luigisante** » Mon Oct 24, 2011 9:09 am

Put up the Chart Table cabinet cover. Room here for a chart-plotter and flush mount radio.

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Started to replace the doorway trim to the forecabin. Lots of fitting needed here.

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The doorway will look nice once I'm done.

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luigisante · Post by **luigisante** » Mon Oct 24, 2011 9:19 am

Finished the plywood template for the remainder of the galley. I was really pleased with the design, once I put it all together. The counter height is perfect.

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The length is sufficient to cover the half pipe and lap the hull liner to give it a factory look.

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The time spent fitting and refitting the top template was obviously worth it. The seams are really tight.

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You can see a piece of teak trim I was considering using on the edge, but I think I am going with the same wood I used on the chart-table which is thicker and has a larger lip and would help keep things on the counter underway. I have been begging scraps of formica from local cabinet makers but no one had pure white, which I think I'll be using as the top for the galley. The front will be the type of plywood sandwich I used on the aft side of the galley to get the proper thickness. The top will overlap the front by 1/4" to make the trim fit properly. This work is very tedious. I have probably had the templates on and off a hundred times, taking small shavings with a hand plane to make them fit tightly. It has been worth the effort. I am seriously behind schedule however. Oh well.

Lou

luigisante · Post by **luigisante** » Sun Oct 30, 2011 4:17 pm

Time to make the finished countertop and galley facia. I need a bit more oak plywood and some white formica. I have to get the pkywood for the settee as well. In the meantime, I've started working on the doorway between the main cabin and the forepeak. First, I cleaned up a piece of trim.

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Then, I dug out the original doors. They need some repair. I sanded them down.

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Then I had to dremmel out the inside of the trim to make some room for fitting.

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This bulkhead has been significantly repaired and I can see from the trim that the epoxy repair is a bit thicker than the original. The repair also encroaches into the port side of the upper opening by a quarter inch. These will need some extra attention fitting the door frame.

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luigisante · Post by **luigisante** » Sun Oct 30, 2011 4:24 pm

Here are the individual door frame pieces going in.

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These sections all fit nicely.
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luigisante · Post by **luigisante** » Sun Oct 30, 2011 4:29 pm

This corner is the only problem and needs adjustment.

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And here it is - rough fitted. Looks good.

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Final fitting and then back to the galley.

Lou

luigisante · Post by **luigisante** » Mon Nov 28, 2011 8:22 am

It's been a busy month at work. Have only had the opportunity to get a few hours in on the boat before last weekend. Made some decent progress though over the Thanksgiving holiday. Using the template and final adjustments, I was able to make the final countertop underlay. I over-cut the top by an eighth of an inch and used a plane to make the final fit. The fit is really nice.

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Applied a layer of contact cement and let it dry. Did the same to the white formica that will cover the substrate. After drying, they'll both get another coat and then I'll bond them together and let them dry before routing the edges flush.

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After that was done, I turned my attention to cutting and bonding the quarter-inch oak veneer that will go on the galley front panel. Here is the oak plywood being measured and cut.

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(con't)

luigisante · Post by **luigisante** » Mon Nov 28, 2011 8:30 am

Once the oak veneer plywood was cut, it was bonded on the plywood template. A five gallon pail of "Kills" primer makes a perfect bonding weight.

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Once the bonding glue completely dries (24 hours), I will be ready to trim the veneer with a router and make the final fitting. At that point, the structure of the galley is done and I can start to concentrate on completing the carpeting in the starboard well and having the settee cut.

I picked up my brackets last week as well.

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The galvanizing looks great. You were all correct, no special prep needed.

The 65F weather this weekend was a real godsend. As long as we don't have a ton of snow like last winter, I should be able to keep progressing on the refit. I'm fairly confident that I will be splashing my boat in the Spring.

Lou

luigisante · Post by **luigisante** » Sun Dec 04, 2011 4:07 pm

Weather has been holding out nicely. This weekend was great weather: sunny and mid-50s. I took advantage of it to try to complete the galley structure. First, I routed the formica top and used the hand-plane to bevel the plywood edges a bit.

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The top fit nicely. I marked it for attaching fasteners to the frame.

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Once the top was fitted for size, the front was attached and marked for final trimming.

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(con't)

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