Our old 1961 Alden Challenger yawl is Alden's first glass hull and deck. The rest of the boat - like the cockpit which has rotted beyond repair - is built of wood.
I have a plan to build a new cockpit, off the boat, in a warm shop. Using a template carefully scribed to fit the perimeter of the coamings and cabin at the bridge/seat deck height,...
...that has been my pattern for a new cockpit built of 3/4" Marine plywood(you can see the template hanging overhead).
The old cockpit was a joy to use, but it had some design problems as well as the fact it was losing strength all around.
This project has been an opportunity to fix what I didn't like in the old cockpit; a better seat channel drain system,...
...trapazoid shaped locker lids for better stowage and access, a stronger all around platform for working the boat(every inch of a cockpit gets walked on). I'm looking forward to a drier, stronger cockpit.
Plus it has been fun to study similar boats and countless photos of cockpit design. Tropical hardwoods like Teak are expensive! I've cut my veneer decking and trim out of Ipe lumber, a very hard, dense and rot resistant species that is 1/3rd the cost of teak wood.
Here, the 'planks' are dry fit. Next, the planks are set in epoxy and the screws are refastened(they act as temporary clamps).
Once the epoxy is dry, the screws are removed - the pilot holes bored to 3/8" to the full depth of the Ipe decking(1/2"), and full depth plugs set in epoxy. The whole deck, including the cockpit sole, sanded flush and the 1/8" seams caulked with traditional black rubber sealant.
The final trick is the outer perimeter Ipe margin trim boards - that won't be adhered in epoxy - will be removed. This spring the new cockpit will be lowered into the void(I haven't plowed out that void yet,...). The outer perimeter of the 3/4" ply will be epoxied and fastened to a perimeter ledge to be installed(later).
Finally, the perimeter margin deck boards will be epoxied in place - sanded - and the last outer seams caulked and finished. The binnacle - manhole - etc. replaced in pre fitted holes cut in the shop. Work so far has been a pleasure at this standing height. It would be a brutal task to do onboard, especially outside in a Maine winter.
I have a plan to build a new cockpit, off the boat, in a warm shop. Using a template carefully scribed to fit the perimeter of the coamings and cabin at the bridge/seat deck height,...
...that has been my pattern for a new cockpit built of 3/4" Marine plywood(you can see the template hanging overhead).
The old cockpit was a joy to use, but it had some design problems as well as the fact it was losing strength all around.
This project has been an opportunity to fix what I didn't like in the old cockpit; a better seat channel drain system,...
...trapazoid shaped locker lids for better stowage and access, a stronger all around platform for working the boat(every inch of a cockpit gets walked on). I'm looking forward to a drier, stronger cockpit.
Plus it has been fun to study similar boats and countless photos of cockpit design. Tropical hardwoods like Teak are expensive! I've cut my veneer decking and trim out of Ipe lumber, a very hard, dense and rot resistant species that is 1/3rd the cost of teak wood.
Here, the 'planks' are dry fit. Next, the planks are set in epoxy and the screws are refastened(they act as temporary clamps).
Once the epoxy is dry, the screws are removed - the pilot holes bored to 3/8" to the full depth of the Ipe decking(1/2"), and full depth plugs set in epoxy. The whole deck, including the cockpit sole, sanded flush and the 1/8" seams caulked with traditional black rubber sealant.
The final trick is the outer perimeter Ipe margin trim boards - that won't be adhered in epoxy - will be removed. This spring the new cockpit will be lowered into the void(I haven't plowed out that void yet,...). The outer perimeter of the 3/4" ply will be epoxied and fastened to a perimeter ledge to be installed(later).
Finally, the perimeter margin deck boards will be epoxied in place - sanded - and the last outer seams caulked and finished. The binnacle - manhole - etc. replaced in pre fitted holes cut in the shop. Work so far has been a pleasure at this standing height. It would be a brutal task to do onboard, especially outside in a Maine winter.