Sunday, September 25, 2011

The Re-assembly Begins

Today was a good productive day for the re-assembly of the owners stateroom.  We made a lot of trips between the storage unit (where we have our wood working tools and room to spread out and work).  We had someone come by and give us a quote on replacing the headliner.  I was a bit surprised at the cost.  The guys were great and do really good work, however for just the owners stateroom (about 5 yards of material) was going to be$1200-$1400.  We really wanted to do a wooden ceiling and thought that would be a problem because it wouldn't breathe, but these guys confirmed that is not an issue if we want to use hard board or wood.  We were going to put "Bead Board" on the ceiling but we really struggled to get each panel so that the slat lines line up, it didn't look good, so we scrapped that idea  We will end up still doing wood, but likely going to do knotty pine varnished 4" wide planks instead.  We can do a tongue and groove on each one to help hold them together and if we start in the middle, we are hoping that it will look better since we can get the planks to run the full length in single sheets with trim to hide the fastening screws that will hold it up against the ceiling beams.

Curved wall on Port Side of bunk
Today we really got quite a bit complete.
  • Ran wire for 2 wall lights and 2 reading lights
  • Installed port and starboard curved hull walls from the bunk to the deck
  • Installed the rear curved wooden wall around the 2 fixed ports
  • Installed the port coach roof panel along the opening port
    Curved wall around the 2 fixed ports
  • Installed the starboard coach room panel along the 2 opening ports
  • Installed / replaced some rotted plywood
  • Installed the bead board above the bunks
  • Installed 1/2" insulation across the whole ceiling 
Adding Insulation to the roof before re-assembly

We still have to dry fit the ceiling planks, and we are deciding if we will remove them and varnish them out of the boat or attempt to varnish overhead on the ceiling.  We will install all of the teak trim everywhere except the ceiling trim until the planks are all mounted so that the trim covers up any small gaps between the bulkheads and the ends of the ceiling planks.  After that is complete, we will install the rest of the ceiling trim, install bungs and sand them all smooth.  Then it is Varnish, Varnish, Varnish.  We always think we will do 10-12 coats and usually quit after about 6 because we are satisfied with the look.
After all the varnish is complete, we will re-install the refurbished/cleaned/polished Beckson opening ports, but are waiting so we don't have to tape around them when varnishing.