Pilot Door Replacement

[CPseudonym]

Originally Posted by FlyWright

Don't look too closely. It'll take some time before I have the time, knowledge, tools and courage to tackle this project as it should be tackled. I'm still in the learning and planning stage.

If my past performance is any indication of future results, this could take a looooong time.

You and I have a lot in common.

[RT Firefly]

Greetings,
Make that three!

[Rob_L]

Make that four... and thanks to everyone for their great suggestions. My wife and I recently purchased a 1991 Nimble Nomad (a 20' "pocket trawler"). The exterior teak (four hand rails, the pilot house door, the running light boards/baffles on top of the pilot house, and some battens under the cockpit seats for storage areas) needs attention, but the lower exterior panel in pilot house door is delaminating. This very timely thread has given me a number of ideas on how to go about this and I just wanted to say "Thanks." Any suggestions on removing peeling varnish/topcoat without damaging the teak or gelcoat would also be appreciated.

Rob

[Phil Fill]

Rob, first use a heat gun to get the majority of the old vanish/paint off than an orbital sander With 80 to 100 grit to get the rest off. With the heat gun just heat enough so the vanish bubbles/start to come up, then with a putty knife to scrape off. At first sneak up on how close/hot, until you get the hang of it. It helps if every year you lightly sand/scuff the varnish and apply a new coat, especially the weather side. If there is not enough time to build a number of thick varnish layers, I will use epoxy with several coats of varnish over.

[RickH]

Rob, You may want to consider Citri-Strip stripper, pretty benign stuff that didn't hurt my gelcoat on the tug. I cleaned up the drips about 10-15 minutes after application and the gelcoat looks fine. The product is available here at Home Depot, and probably at other places as well. No affiliation with them, but a fairly decent product. I wouldn't try to mask off the gelcoat as you're bound to get some underneath the tape and that won't be good. Caviat: it works slowly, unlike the methyl chloride based products, so give it plenty of time to work. No nasty fumes to contend with, and it looks like a melted Dreamsicle !

RickH