Lower Side Panels
 
The lower side panels of both the cuddy cabin and pilot house are a sandwich of 1/4” ply, 1/2” foam, and 3mm ply. The first step was to attach the 1/4” ply to the deck from the rear bulkhead to the front cuddy bulkhead. This is a total of 14’, so a butt joint was required in the straight section of the pilot house. (The joint is behind the clamp jig wrapped in plastic to provide a release from the epoxy). I built a series of clamping jigs canted at 5° and screwed them to the deck. This kept the side panel in the correct position until the epoxy set. The lower edge was set with bronze ring shank nails driven into the deck edge. Along the top edge is a 1/2” piece of clear Doug Fir that is pre-beveled to match the angle of the cabin top. It is used both as a nailer and guide to trim the side panels.
 
Monday, May 14, 2007