Reply
 
Thread Tools Search this Thread Display Modes
 
Old 08-15-2020, 02:40 PM   #1
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Building New Pilothouse Doors for a Bluewater Trawler

Time to build new doors for the Pilothouse. This is a continuation of my "Bluewater 40 Pilothouse Replacement" thread. I felt a new thread would be easier to follow.

Picture 1 shows the crack on the port door. The door is constructed out of 3/4" plywood of questionable Chinese origin, sheathed in fiberglass cloth with polyester resin. Water leaked past the window seals and saturated the plywood core.

The leaking window and the wet core were pointed out by Matt Harris during a pre purchase survey in 2000. Sales price was reduced to cover replacement.
There were other issues with higher priority that needed attention first so I did a temporary repair after drying the core. The repair lasted 20 years! The plywood eventually delaminated and swelled creating cracks in the door skin.

Picture 2 and 3 shows the dry delaminated core.

Picture 4 and 5 shows the interior side of the door after the window was removed. I will be replacing the windows with new glass.

I will be building a new starboard door also. The starboard door is not delaminating but starting to warp.
Attached Thumbnails
100_3766 (Medium).jpg   100_3778 (Medium).JPG   100_3780 (Medium).JPG   100_3790 (Medium).jpg   100_3791 (Medium).jpg  

__________________
Advertisement

syjos is offline   Reply With Quote
Old 08-15-2020, 03:30 PM   #2
Guru
 
Comodave's Avatar
 
City: Au Gres, MI
Vessel Name: Never Say Never
Vessel Model: President 41 DC
Join Date: Jul 2015
Posts: 10,803
I made a sliding door for a previous boat out of 1Ē starboard. Zero maintenance.
__________________

__________________
Boat Nut:
If you are one there is no explanation necessary.
If you arenít one, there is no explanation possible.
Comodave is offline   Reply With Quote
Old 08-15-2020, 03:32 PM   #3
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Picture 1. Traced the old window opening to MDO, cleaned up the straight lines and curves. Cut out center with jig saw and sanded the MDO to the line to create an accurate, smooth pattern for routing openings in new doors.

Picture 2 shows the pattern being checked for accuracy. There is a cleat on the right side to index the pattern to the door edge.

Picture 3 shows the pattern for window glass being sawn. Using the pattern created above, traced a line 5/8" larger than the opening.

Picture 4. Will ship the pattern out to have tempered glass made.

Will be buying two sheets of 3/4" mahogany marine plywood next week to build the doors. Will compare Aquatek and Sande/Virola plywood and select the one which is flattest.

Will build doors in similar fashion to the old doors with a few improvements. The window openings and glass landing will be epoxied prior to window installation to mitigate water incursion. The bottom of the door where it rides on the track will be improved with HDPE.

The plywood doors will be sheathed with glass cloth and epoxy.

I looked at several other door building methods:

A foam cored door. Wood framing with 1/8" Okoume plywood on either side, polyurethane foam coring, encapsulated in glass and epoxy. Too much work.

A door made out of Starboard. Difficult to glue, the white doesn't match boat paint, paint will not stick, hard to repair or hide mistakes, too much expansion with hot weather. I don't enjoy working with plastic as much as I enjoy working with wood.
Attached Thumbnails
100_3785 (Medium).jpg   100_3779 (Medium).JPG   100_3788 (Medium).jpg   100_3781 (Medium).JPG  
syjos is offline   Reply With Quote
Old 08-15-2020, 03:46 PM   #4
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Quote:
Originally Posted by Comodave View Post
I made a sliding door for a previous boat out of 1” starboard. Zero maintenance.
I seriously considered making the doors out of Starboard after reading a previous post of yours last year or so. It seems like the ideal material.

I looked at a boat that had 3/4" Starboard sliding doors last summer. The owner complained that when it got hot, the door would warp slightly and make opening and closing difficult. 1" like you suggested would be more stiff but the tracks on Sandpiper is made for a 3/4" thick door. I even looked at shaving 1/4" off the top and bottom to make the door fit but other reasons had me look at other methods.

Fiberglass encapsulated doors will be 0 maintenance too.

I listed the reasons for not using it on the next thread.
syjos is offline   Reply With Quote
Old 09-12-2020, 02:29 PM   #5
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Purchased two sheets of 3/4" Marine Sande plywood which is mahogany.

Plywood ripped to correct width in picture 1.

Sawing bottom and top of doors at proper angle with a saw guide. Pic 2

Cleaning up the cut with a router using a straightedge for a guide. Pic 3
Attached Thumbnails
100_3792 (Medium).jpg   DSCN0062 (Medium).JPG   DSCN0063 (Medium).JPG  
syjos is offline   Reply With Quote
Old 09-12-2020, 02:38 PM   #6
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
The opening for windows traced with pattern, rough sawn with Jig saw.

Picture 1 shows opening being trimmed using a router with pattern.

Edge rounded with trim router. Pic 2

Finished exterior of window opening with radiused edge. Pic 3
Attached Thumbnails
DSCN0052 (Medium).JPG   DSCN0053 (Medium).JPG   DSCN0054 (Medium).JPG  
syjos is offline   Reply With Quote
Old 09-12-2020, 02:51 PM   #7
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Using the window opening pattern to create another pattern 7/8" larger all around for the glass landing. Pic 1

Routing the glass landing on the back side of door using the pattern created above. Pic 2

Finished glass landing recess. Pic 3

Trial fit of glass landing using the glass template. Pic 4

View from the outside. Pic 5
Attached Thumbnails
DSCN0056 (Medium).JPG   DSCN0055 (Medium).JPG   DSCN0059 (Medium).JPG   DSCN0060 (Medium).JPG   DSCN0061 (Medium).JPG  

syjos is offline   Reply With Quote
Old 09-24-2020, 05:32 PM   #8
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Both sides of the door precoated with epoxy and allowed to dry. Nicks and low spots filled with System Three Quickfair and sanded lightly after drying.

Applied 5.6 oz fiberglass cloth to exterior of doors with System Three Silvertip Epoxy.

The cloth was draped over the doors, epoxy poured on and spread with a squeegee. Excess epoxy squeegeed off and the fabric pressed down with an aluminum finned bubble roller and squeegeed again to remove excess epoxy.

The fiberglass is for sheathing only, not adding strength. The 5.6 oz glass fabric will insure uniform epoxy thickness and provide impact and puncture resistance. The glass/epoxy surface provides a hard smooth surface for paint.

The interior side will be glassed tomorrow..
Attached Thumbnails
DSCN0065 (Medium).JPG   DSCN0066 (Medium).JPG  
syjos is offline   Reply With Quote
Old 01-25-2021, 07:25 PM   #9
Veteran Member
 
KingBuffalo's Avatar
 
City: seattle
Vessel Name: The Lady J
Vessel Model: Bluewater 40 Pilothouse
Join Date: Aug 2019
Posts: 64
Did you ever finish these?
KingBuffalo is offline   Reply With Quote
Old 01-25-2021, 08:42 PM   #10
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Quote:
Originally Posted by KingBuffalo View Post
Did you ever finish these?
I took a break after getting both sides glassed. Had other projects in the fall at home and boat.

Started work on the doors two weeks ago. Will be posting soon with pictures.
syjos is offline   Reply With Quote
Old 01-25-2021, 09:55 PM   #11
Veteran Member
 
KingBuffalo's Avatar
 
City: seattle
Vessel Name: The Lady J
Vessel Model: Bluewater 40 Pilothouse
Join Date: Aug 2019
Posts: 64
Great! I like You’re posts because you’re a true craftsman and you have the same boat that I have.
KingBuffalo is offline   Reply With Quote
Old 01-26-2021, 12:30 AM   #12
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Quote:
Originally Posted by KingBuffalo View Post
Great! I like Youíre posts because youíre a true craftsman and you have the same boat that I have.

Thanks for the compliment.

Where do you moor the BW?

You work at my favorite Marine Supply store!
syjos is offline   Reply With Quote
Old 01-26-2021, 11:01 AM   #13
Veteran Member
 
KingBuffalo's Avatar
 
City: seattle
Vessel Name: The Lady J
Vessel Model: Bluewater 40 Pilothouse
Join Date: Aug 2019
Posts: 64
She’s currently near Portland, OR but the plan is to move her up to the Sound this summer. Probably Shilshole.
KingBuffalo is offline   Reply With Quote
Old 01-26-2021, 11:11 AM   #14
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Quote:
Originally Posted by KingBuffalo View Post
Sheís currently near Portland, OR but the plan is to move her up to the Sound this summer. Probably Shilshole.
Did you buy it recently?
syjos is offline   Reply With Quote
Old 01-26-2021, 11:18 AM   #15
Veteran Member
 
KingBuffalo's Avatar
 
City: seattle
Vessel Name: The Lady J
Vessel Model: Bluewater 40 Pilothouse
Join Date: Aug 2019
Posts: 64
I bought her about a year ago. She needs a bit of work to get her up to snuff though.
KingBuffalo is offline   Reply With Quote
Old 01-26-2021, 11:30 AM   #16
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Quote:
Originally Posted by KingBuffalo View Post
I bought her about a year ago. She needs a bit of work to get her up to snuff though.
Which BW in Oregon did you purchase?

Can you post some pictures in the BW section? Especially with the work you will be doing.

We have a small BW owners group here on Puget Sound. We have a rendezvous in the spring.
syjos is offline   Reply With Quote
Old 01-26-2021, 11:36 AM   #17
Veteran Member
 
KingBuffalo's Avatar
 
City: seattle
Vessel Name: The Lady J
Vessel Model: Bluewater 40 Pilothouse
Join Date: Aug 2019
Posts: 64
The Lady J. I’ve never been one to take pics and post the work I’m doing, but I’ll consider it for some of the work I’ll be doing. The next big thing will be replacing some decking. Basically everything on the foredeck level including the area behind the Portuguese bridge. Lots of soft stuff up there and a leak that drips onto the v berth cushion. Then hull work. Blisters.
KingBuffalo is offline   Reply With Quote
Old 01-26-2021, 11:38 AM   #18
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Quote:
Originally Posted by KingBuffalo View Post
Sheís currently near Portland, OR but the plan is to move her up to the Sound this summer. Probably Shilshole.
Now I know why you asked about seaworthiness and following seas earlier.

The trip from Portland to Puget Sound will be sometheng to look forward to and fun, maybe?
syjos is offline   Reply With Quote
Old 01-26-2021, 11:50 AM   #19
Veteran Member
 
KingBuffalo's Avatar
 
City: seattle
Vessel Name: The Lady J
Vessel Model: Bluewater 40 Pilothouse
Join Date: Aug 2019
Posts: 64
Hopefully. It’ll be my first time on the open ocean. The closest I’ve been is the Strait of Juan de Fuca in my sailboat, and that was just a trip to the San Juans so I can barely make that claim. It’ll also be my first time crossing the bar, but as long as I time it right I don’t expect problems there.
KingBuffalo is offline   Reply With Quote
Old 01-26-2021, 12:32 PM   #20
Guru
 
syjos's Avatar


 
City: Gig Harbor
Vessel Name: Sandpiper
Vessel Model: Bluewater 40 Pilothouse Trawler
Join Date: Nov 2012
Posts: 2,267
Quote:
Originally Posted by KingBuffalo View Post
The Lady J. Iíve never been one to take pics and post the work Iím doing, but Iíll consider it for some of the work Iíll be doing. The next big thing will be replacing some decking. Basically everything on the foredeck level including the area behind the Portuguese bridge. Lots of soft stuff up there and a leak that drips onto the v berth cushion. Then hull work. Blisters.
Yikes! Will you have covered moorage to do the outside work?

Is your hull cored or solid?
__________________

syjos is offline   Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



» Trawler Port Captains
Port Captains are TF volunteers who can serve as local guides or assist with local arrangements and information. Search below to locate Port Captains near your destination. To learn more about this program read here: TF Port Captain Program





All times are GMT -5. The time now is 05:56 PM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2021, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2006 - 2012
×