After basically tearing the interior of my boat apart a couple years ago and then just letting it stay that way while I enjoyed the fun part of boat ownership (sailing it!), the reconstruction has commenced!

I made a  post a while back about doing all work and no play, but I finally realized it can’t be all play and no work either if I want to get this project completed! 🙂

I took a couple of my days off last week to begin the reconstruction. You might recall a post in which I measured the affected shelving boards I needed to replace.  I had intended on using those measurements and just cutting the necessary plywood, but I figured that could be a problem if, for instance, my measurements were off even the slightest. So I decided to make templates for the boards I needed instead.

That way there’d be no question as to the fit.

Cardboard template ready for cutting. That's my sweat drops on there...it was HOT!

Cardboard template ready for cutting. That’s my sweat drops on there…it was HOT!

Cardboard templates cut to size

Cardboard templates cut to size

After making the cardboard templates and cutting the plywood to match the templates, it was time to install.

I aligned everything up and thankfully they fit properly. I used joining plates on the underside of the joints to provide a bit more support. I used an industrial-grade adhesive to secure the edge of the new plywood to the fiberglass lip that protruded from the hull wall.

Here’s some in-progress photos:

After cutting the old shelf. Starboard v-berth.

After cutting the old shelf. Starboard v-berth.

Repair joint between old shelf and new. View from underneath.

Repair joint between old shelf and new. View from underneath.

Repair joint between old shelf and new. Starboard v-berth.

Repair joint between old shelf and new. Starboard v-berth.

Next step will be to re-attach the shelf rails in the port quarter berth and the v-berth then put some carpet on the hull walls. I had considered just painting the interior hull walls, but after seeing the results of trying one coat on one wall, I think it’d be best just to replace carpet. More on that in my next post.

Anyone have any thoughts on how this is coming along and my methodology?

Thanks!

Mike