Completing Cabin & V-berth Trim

April 29, 2020

I managed to get a few hours on the boat today, with a focus on completing the cabin and v-berth trim work.  What is left is dry-fitting the v-berth fiddles and then final shaping by sanding and easing edges for comfort.  I also need to permanently install a couple of the longitudinal trim pieces with epoxy resin, and then paint the v-berth insert.

In the photo below, I made the final dimensioning cuts on the fiddles, and then moved on to measuring for the fasteners.

In the shop, I chose three #10 machine screws per fiddle, port and starboard.  These fasteners will include finish washers, and be backed by washer and nylon locking nut.

I managed to mark, pre-drill, and then tap for the #10 machine screws - 3 per side.  I then installed the fiddles.  With that completed, all trim work was checked off the list.  Next step: remove the trim, final sanding, application of teak oil, and then final installation.

I removed all trim from the boat and carried it over to the shop.  I disassembled the v-berth insert, and installed bungs in the v-berth insert trim.

I then applied tape to protect the inserts center trim piece, and prepped the board for primer paint.  After mixing the Interlux Primekote and waited through the 20-minute induction / catalyzing period before applying the primer.  I removed the fasteners from the underside of the insert and applied primer paint to that surface.  After applying the primer paint, I reinstalled the screws to use them as a platform in order to paint the top surface.

I then applied the primer paint to the top surface of the v-berth insert.

With the painting complete, I turned my attention to working each of the trim pieces making up the v-berth and cabin trim.  I sanded through 150 and 180-grit discs until  I reach a surface ready for teak oil, which will come over the next few days.

Total Time Today: 3.5 hrs

V-berth Trim (Part 2)

April 27, 2020

I had only a little bit of time to work on the Allied 24 today, so I chose to continue working on the v-berth trim.  In a previous work session, I had assembled the v-berth insert, to include epoxy-gluing the center trim piece.  Today, I removed the protective tape and generally cleaned up the surfaces by hand-sanding, easing the sharp 90-degree edges on the center trim piece.  Next steps for the v-berth insert was to disassemble the outboard trim boards, paint, and then reassemble.

Next, I worked on the v-berth fiddles, located just aft of the insert.  After rethinking how I wanted the trim to come together in the v-berth, I needed to extend both fiddles by roughly 3/4".  In the previous session, I glued extensions on the ends of the fiddles, replicating the angles to which they would encounter the aft portion of the v-berth insert.  Today, I carefully removed material in the extension to continue the rabbit cut into the surface that would mate with the v-berth itself.

After removing the unwanted material from the extensions, I thoroughly sanded the surfaces, including easing edges, to prep for installation.

Total Time Today: 1 hr

Installing Cabin Trim & Applying the 5th Coat of Topsides Paint

April 25th and 26th, 2020

Over the last couple of days, I have been working to prep the topsides for her 5th coat of paint as well as addressing various tasks associated with the cabin and v-berth trim.  Early this morning, I applied the 5th coat of Alexseal - which laid down very nicely!

Yesterday was mostly spent working on the trim components.  The first of the trim I installed, with a permanent installation by use of epoxy, were the inboard edges of the primary bulkheads.  These pieces would never need to be removed, so I decided to bed them in thickened epoxy, using 406 colloidal silica.  I sanded the inboard edges of the bulkheads to expose raw would, and then followed that up by vacuuming up the sanding debris and cleaning all surfaces with acetone.  I wetted the surfaces to be glued with epoxy and followed that up with application of the thickened epoxy resin.  Three-point clamps were used to keep the trim tight to the bulkheads, with cardboard protecting the painted surface of the bulkheads.

With the bulkhead trim in place and curing, I moved on to the settee trim in the cabin.  Four #12 machine screws would secure each trim board (fiddle) to the settee, and would use a finish washer. 

The small section of trim aft of the primary settee fiddle would be secured by three #6 wood screws, also with a finish washer.

I placed the fiddle on the settee, and then marked for where fasteners would be used.  I evenly spaced the fasteners along the length of the trim piece, and then pre-drilled in order to tap the holes for the threaded fasteners.  The installation went without issue after spending time thinking through the location of the fastener on the trim piece and the method of securing them.  The small, aft section of trim cannot be seen in the picture below, but resides just aft of the primary settee fiddle and outboard of the landing platform.  In fact, this small section of trim is fastened to the side panels of the landing platform itself.

Having had previously cut the various trim components for the v-berth's removable insert (well, almost all of them), I made some additional measurements and plans to complete the assembly of it.  I removed the insert and trim pieces, taking them back to the shop, and proceeded to assembly them.  I first assembled the trim components, countersinking #10 wood screws at the butt joints, and then fastened that frame to the meranti plywood.  I sanded the edges to ease them for ease of handling and comfort, and then set the insert back in place.  From here, I gathered some additional measurements using the v-berth trim boards just aft of the insert, and carried those measurements (and the v-berth trim boards) down to the table saw.  I needed to fill in roughly 3/4" of length between the v-berth trim and the insert trim, so I transferred the angles cut onto the ends of the trim to the table saw blade with a bevel, and proceeded to cut the filler pieces that I required.  While at the table saw, I also cut a piece of trim for the center portion of the v-berth insert.

I carried the insert, its center trim piece, and the v-berth trim boards with their extension pieces back to the shop, but I was out of time for the evening.  I'd pick up things in the morning.

I arrived at the shop well before sunrise in order to complete the glueing that was required on the v-berth trim boards and the insert's center trim piece.  I wanted to use this pre-dawn time to knock out the epoxy work prior to getting into the topsides paint application.  This task was straight forward: cleaned the surfaces to be glued with solvent, wetted the surfaces with resin, and then assembled them with some additional thickened epoxy resin.  I have a bit of finer detail work to clean them up for installation, and that would come once they had fully cured.

I also glued the v-berth insert's center trim piece in place, protecting the surrounding surfaces with tap and assembling with clamps.  It was now time to paint!

I had a bit of minor sanding to do on a couple spots, so I knocked that out rather quickly and got straight into prepping for the paint application.  Back in the shop, I mixed the pot of two-part Alexseal topsides paint and set it to the side for its induction/catalyzing period.  While the paint was doing its thing, I wiped the surface of the boat down thoroughly.  I first used slightly water-dampened rags to pick up a majority of the remaining paint dust, and then came behind that with rags dampened with a solvent to complete the prep.

Paint went on with no issue, and the finish coat ratio of thinner I used behaved well in the early morning temperatures, leveling out beautifully.

Other than the random small insect, which should not impact the paint job harshly, the finish coat looks beautiful.  On to the cockpit and deck paint!

Total Time over 2 Days: 6.75 hrs

Sanding the Topsides in Prep for Final Coat

April 24, 2020

In another marathon round of sanding, I was able to sand down the 4th coat of topsides paint (Alexseal), and in preparation for the final coat to be applied this weekend.

I used 320-grit sand paper to scuff the surfaces around the boat.  Looking forward to getting the topsides paint finished.

Total Time Today: 4.25 hrs

Topside Coats 3 & 4

April 19, 2020

With yesterday afternoon's hand-sanding marathon accomplishment, I felt the only natural follow up would be to apply the subsequent rounds of topside paint.  I arrived at the boat early to begin the process for prepping the painting surfaces.  I wiped down the hull with a damp rag, and then followed that up with solvent-dampened rags to remove the balance of the sanding residue.

While I was cleaning the hull, the two-part paint was catalyzing in the shop.

I thinned the paint appropriately after completing the hull preparations, and then began the paint application.  It took nearly and hour to get the third coat on, and decided to go for another coat while I was at it early in the day.

The fourth coat went on fine.  The plan is for a fifth and final coat of paint sometime next weekend.

Total Time Today: 3 hrs

Sanding the Topsides (for 3rd Coat of Alexseal)

April 18, 2020

The day's work was fairly simple. There wasn't use of a bevel to measure and transfer angles to the table saw, there wasn't epoxy resin involved in the day's chores, drill bits stayed tucked away, as did the taps, the planer sat idle, it was a day of simply sandpaper and sweat.  

The topside finish coats are about to be applied, and so that meant a bit of fine-tuning the surfaces....hand-sanding with 320-grit paper...the entirety of the topsides!

Yes, it is as grueling as it sounds, and possibly more so since hand-sanding topsides really doesn't 'sound' that bad!  Somewhere along the way, one looses oneself...and then finds oneself again, happy to be reunited and at the last bit of surface to sand.

Tomorrow's forecast is for cloudy conditions in the morning and mid-70's.  The third coat is scheduled for the morning - barring my shoulders seizing up after today's marathon session.

Total Time Today: 3.5 hrs

V-Berth Trim and Test-Fitting the 12V Battery

April 17, 2020

The focus of today was to get the v-berth trim finished, or at least roughed in.  When I refer to "roughed in", I mean that the dimensions of the individual trim pieces are cut so that they fit, but that rounding and smoothing of the edges still needs to take place.  In addition, pre-drilling for fasteners, oiling the teak, and final installation would then follow the rough in.

Prior to getting to the trim, I took a moment to test-fit the 12V battery in the newly installed battery tray.  Granted, the location is not ideal; however, the light-weight lithium battery allows for easy installation and removal.  Now, keep in mind that the Torqueedo 48V battery will be installed just forward of this 12V lithium ion battery, preventing ease of access.  Since the lithium ion batteries are fairly maintenance-free, this solution will work.  

A close up of the battery in its tray, without restraints mind you.

If push comes to shove, and the battery required removal, it is light enough that the battery could be removed by rotating it out onto a towel, for example, and then pulled outboard far enough to pull into the starboard (or port) settee.  Now for the trim...

I began by fabricating trim covering the intersection of the forward face of the primary bulkhead and the aft of the v-berth platform.  This was fairly straight forward, and completed for both port and starboard sides.  I then began on the trim for the inboard edge of the v-berth platform itself.  I chose a 3" height, with 1" above the settee and 2" of rabbit to sit flush with the vertical surface of the v-berth itself. 

I completed the starboard trim, covering the inboard edge of the v-berth...

...and then completed the port side.  On both sides, I had obtuse angles to deal with for a tight fit, as well as having to notch in the athwartship trim boards, so I fiddle a bit until I was satisfied with the fit.

I worked my way forward to the location of the old head (removed, and through-hulls glassed in).  This area had held a board to fill in the v-berth platform, and I wanted to replicate that for best use of space.  With trim required to be consistent and aesthetic, and since I need the board to be removable, I could not then fasten the trim to the v-berth as that would prevent the board from lifting out.  I would then need to fasten the trim pieces to the removable board itself.  With the plan settled on, my next move was to cut a board to fit the space.  I templated the space using hot-glut and a series of stir sticks (aka tongue depressors).

I carried the template back to the shop, transferred it to a piece of 3/4" meranti, and then removed it from the stock.

With a bit of minor dimensioning and sanding, I arrived at a good fit.  My next issues was that the port cleat supporting the board was dropping in height as it moved from stern to bow.  I removed the four screws, re-set its orientation, pre-drilled three new holes, and then reinstalled the cleat.

With the board in place and dimensioned, I began to fabricate the various trim pieces that would be fastened to it.  Some where straight forward; some required hand-plaining.

In the end [of the day], I had 90% of the v-berth trim completed, or roughed in.  I still would need to complete the aft pieces of trim on the removable board; small, 2.5" lengths of trim, but super finicky!

The interior is really beginning to come together.  

Total Time Today: 5.25 hrs

Balance of the Cabin Trim

April 16, 2020

Working to complete the trim within the cabin and v-berth; I have set a goal to complete all trim work by the coming weekend.  Today, I set out to complete the cabin trim.  I had, in the prior work session, fabricated the inboard edge trim for the primary bulkheads, so I was now ready to complete the balance of the trim on the settees.  I started by taking measurements and then selecting off-cuts of the teak stock with intent to fabricate the trim at the forward end of the settees where they meet the aft face of the primary bulkheads.  The dimensions chosen were 1.25" in height by .75" in width.  I made the necessary cuts, including rabbits to accept a fiberglass flange, and then set them in place.

Next, I completed the trim by creating a fiddle for the inboard edge of the settees.  I originally had planned to run a continuous length of trim from the aft face of the primary bulkhead and aft to just forward of the interior surface of the cockpit well.  This would have allowed for the trim to run alongside the landing platform / battery box for the 48V Torqueedo battery.  However, I chose to create two pieces, the longer trim piece running from the aft face of the primary bulkhead to the forward face of the landing platform, and a second piece completing the run back to the interior surface of the cockpit well. This would allow for flexibility and ease in disassembling the landing platform in the event that service is require.

With the inboard settee edge trim completed, I could now move on to the v-berth trim.  The v-berth trim would have to wait another day, however.  

I still need to come back and shape the trim boards, and ease edges, and of course oil them.  

Total Time Today: 4 hrs

Primary Bulkhead Trim

April 14, 2020

The focus of the day was to fabricate the trim for the primary bulkheads.  I started by taking measurements of the inboard edges of the port and starboard bulkheads, and then selecting teak stock to support the efforts.  I jointed one edge of the teak stock, and the cut to dimension the required trim blanks.  The dimensions that I arrived at for the bulkhead trim was 1.25" by 7/8".  Once trimming to the appropriate lengths, I set out to cut the channel in the trim boards.  

I removed the interior "meat" of the channel through several passes on the table saw, and came back with a chisel to clean up the surfaces.

There were a few slight modifications once I began test-fitting the trim pieces in the boat, but I quickly dialed in the final dimensions.  Like I had done with the landing platform trim, I stopped at the rough shaping and dimensioning of the trim work and will come back later to ease edges and smooth out surfaces.

Total Time Today: 1.5 hrs