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Old 05-15-2019, 06:21 PM   #4
syjos
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City: Gig Harbor
Country: USA
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 734
After the framing was removed, 1/4" precoated plywood was cut, fitted and bonded to the top cap and new bottom frame to enclose the front portion of the PB.

The sides of the PB were previously hollow, which contributed to the wood rot. In order to rebuild the PB sides without a cavity, structural foam was used to construct a plywood - foam - plywood sandwich. Areas on the sides, where rails and cleats will be fastened were backed with 1/2" plywood blocking. 1/2" structural foam was trimmed to fit around the blocking and glued to the inside of the 1/2" plywood outer skin and topped with a 1/4" inner plywood skin glued to the foam. The whole structure was vacuumed bagged until the epoxy adhesive cured.

The front of the PB was laminated as one continuous lamination, without a break for the door, in order to maintain a smooth curvature. Plywood bulkheads were glued to both sides of the door opening and a plywood step at the bottom. A frame was fabricated for the door itself and glued to the inside of the door skin leaving a 1/16" gap between the door frame and surrounding bulkheads and step. The plywood skin was cut between the door frame and surround.

The original PB door was also hollow and rotted. The new door frame and skin was reinforced with foam and plywood after separation from the front of the PB.

The holes from temporary fasteners were filled and the whole structure was faired, corners rounded and covered with 10 oz glass cloth with epoxy.

In the first pic, you can see the rear returns that were painstakingly restored. It is darker.
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