Door Project

While reasoned thought was away on holiday....I decided to launch on rebuilding the cabin doors and FB steps. Both sliders and the steps were showing their age: joints coming apart, punky plywood panels, badly peeling/absent finish etc. The first step was to template and fab some temp/ghetto doors out of pine and OSB to keep the boat closed up. I'm neck deep in the project now but can see light at the end of the tunnel. I'll post more pics detailing the odyssey soon.

I did same thing last winter . New doors and tracks . It's a lot of work but you'll be glad you did it .

Me too!

Small world I am in the middle of the same project. Your temp door looks much more profesional than mine. The door is an odd design as the door is about a foot wider than it needs to be. This leaves the inside teak exposed to the weather. The door has wheels on a stainless track that keep the door elevated 1 1/2" and let a lot of air and some water in. I will be following Beach Houses lead and changing to a UHMW poly tracks. Today is finally varnish day. Thanks for the recent TF discussion on penetrating epoxy. You can see in the last picture the thin epoxy I layed into the bottom seam. I thought about doing the entire door with it but the color is way to dark. Cant wait to see your final pictures.

More Pics

So far the corner joints have received have loose tennons, all holes or damaged areas filled with mahogany, old plywood panels removed, edge profiles re-cut, 2 coats of epoxy on the exterior face and edges. Color matching the Hydrotech Meranti plywood to the teak has been a challenge but I think I'm in the ballpark.
Dave, your door is coming along nicely! Looks like you've had to patch with mahogany as well. Something tells me that I'll be wishing I had your cap and rub rails about half way through that phase.

Can you please say where you purchase your sliding door track and hardware.

Not sure what method you are asking about. You can get wheels from Swisco.com and UMHW poly at Plastic Sheets, Plastic Rods, Plastic Tubing - Plexiglass & More
There are several discussions on TF for door track repairs.

Aft Deck Capt said:

Something tells me that I'll be wishing I had your cap and rub rails about half way through that phase.

Click to expand...

That’s funny. There is a boat like mine with a teak cap rails and it looks great. I wouldn't enjoy maintaining it but it would eliminate the annoying cracks I have at my rail stanchions.
Dave

Almost done

Door is refinished and ready to go to the boat. Eight coats Epifane clear and two coats of hand rubbed finish. Waiting on some warmer conditions to install. I have some gelcoat to fix before the door track is installed. Sure hope this works. It has to be better than the wheels.

Awesome job! I love it when a project is undertaken not only to refurbish, but to improve the original design!

Looking forward to seeing how the new sliders work out. I need to do the exact same thing to my door.

That door's going to slide like a greased pig in a mud fight. Nice!

Looks good Dave .That's what I used on my track also . I only used it on the track . I wish I would have put it on the bottom of the door also like yours . Mine slides good biut yours will slide great and UHMW will last a long time . I also used Epifanes on my doors and caprails .

I know how much work it is for you but you're gonna love the results .
Great job

Is there something to keep the door from sliding from slight movement? Does it have a normal marine positive latch when closed?

If not and it slides too easily...I have had mine wiggle open from wind, vibration and head seas.

I have heard others that also need some kind of tensioner to keep the door in position for those without latches.

psneeld, this door doesn't have a latch. It has a dead bolt on the inside that pins the door open or closed. I will have to keep an eye on it. It wouldn't be good if it worked its way open due to wave action when I am away from the boat. I think a good handle and latch will be an improvement for another day. My other door has a latch and key lock.

fryedaze said:

psneeld, this door doesn't have a latch. It has a dead bolt on the inside that pins the door open or closed. I will have to keep an eye on it. It wouldn't be good if it worked its way open due to wave action when I am away from the boat. I think a good handle and latch will be an improvement for another day. My other door has a latch and key lock.

Click to expand...

Mine has a really cool deadbolt...but no simple latch so I try and keep the track 1/2 way clean...so the door slides..but not too easily.

Thus my dilemma with improving the slides on my door...

Dave, excellent work on the door! I just checked out your site and must say that you are an inspiration.
My project was interupted by a week of the flu followed by a week of catch up. Just installed the meranti plywood panels and milled some small cove molding out of mahogany to trim the cabin side of the panels. I hope to start the finishing stage soon.

Aft Deck Capt said:

Dave, excellent work on the door! I just checked out your site and must say that you are an inspiration.
My project was interupted by a week of the flu followed by a week of catch up. Just installed the meranti plywood panels and milled some small cove molding out of mahogany to trim the cabin side of the panels. I hope to start the finishing stage soon.

Click to expand...

Cant wait to see it.

Aft Deck Capt said:

Dave, excellent work on the door! I just checked out your site and must say that you are an inspiration.
My project was interupted by a week of the flu followed by a week of catch up. Just installed the meranti plywood panels and milled some small cove molding out of mahogany to trim the cabin side of the panels. I hope to start the finishing stage soon.

Click to expand...

My doors are overdue for repair and new varnish. I'm trying to think of some excuse that Pack Mule will fall for allowing me to send him my doors for his care and attention. His doors look perfect!

Overdue Progress Pics

I should have uploaded these last summer.

The rails and doors will have been back on the boat since last June. For the foreseeable future our only option for moorage is out in the open, so I'm really hoping that the extra effort will buy extra time between re-coating.
The focus has been to prevent water from entering joints...if possible.

The working pics show the dado that the BS1088 plywood was epoxied into and the old frame screw holes being plugged.
The closeups show a sliver of mahogany epoxied between the butt joints and the back of the joint reinforced with epoxy & FG. (note PO glass scratches)
I used brass inserts in the teak handles to make them easy to remove for re-coating. The screw heads as well as the handle (helm door) were recessed to clear the jam.

This year I plan to add UHMW tracks like Fryedaze and Pack Mule used.

It feels good the have this done....but it only highlights the remaining work!

Nice work Eric! They will look great for a long time.

WOW, that's all I can say!