Easy solution for Catalina 310 companionway crib boards

Jul 28, 2024
18
Catalina 25 Portland, OR
Hey 310 friends,

My 310 came with Zarcor companionway doors, and no crib boards. The doors are great. But, I've entered the Pacific Northwest Offshore race (from the Colombia River to Victoria) and one of the safety requirements is traditional crib boards that are lashed to the boat.

I've posted a wanted ad over in the classifieds, but if that doesn't come through I need to make some. I'm trying to think of the simplest, cheapest option. I should be able to measure the boards from another local 310 owner. Since these don't need to be fancy, maybe I could just cut them out of marine plywood instead of teak? Maybe even Starboard? Could I forgo the interlocking lips that I definitely don't have the right tools to cut? Any other ideas?

Thanks!

Max
 

jssailem

SBO Weather and Forecasting Forum Jim & John
Oct 22, 2014
22,516
CAL 35 Cruiser #21 moored EVERETT WA
Could I forgo the interlocking lips
First, starboard cuts like wood. For boards of any size and thickness you may defeat the goal of “don’t need to be fancy”; which sounds like cheap is good.

To arrive at a water shedding lip, cut the horizontal boards on an angle so that the outer side is a little longer than the inside of the board. A table saw, or even a skill saw can be set at an angle to let water run die the outside and not into the cabin.

There is a starboard like material I discovered at the boat show. It is called “seaboard.” I have no source. The guy displaying it has a shop in Ballard WA.
 
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Jul 28, 2024
18
Catalina 25 Portland, OR
Thanks for the reply! Indeed I was probably overthinking that edge joint. I do have a table saw and could just set it at an angle. I like the idea of a starboard like material if the price is right as it would avoid the need for any finishing and would have nicer edges than plywood. Given these are only to be used for a few days, this could be a cheap and cheerful route.

I’ll see what I can find on seaboard.
 

dmax

.
Jul 29, 2018
1,125
Telstar 28 Buzzards Bay
Starboard won't be cheap and its heavy. If you're just going to use them for a few days, I would just make them out of exterior grade plywood, sand and round the eges and paint with exterior house paint.
 

JRacer

.
Aug 9, 2011
1,355
Beneteau 310 Cheney KS (Wichita)
I replaced the wood boards on my First 310 with Seaboard. Cut on an angle at the bottom (mid-section) so they mate nicely and prevent water intrusion. Seam is not very visible. Cutting was done with a table saw, jig saw and router. Used the old boards as a template. Worst part was getting the top curved dimension correct. Took a redo for the top piece but had enough material to accomplish that. Had to redo the top piece because I had not allowed for the loss of height resulting from the overlap created by the 45 degree cut at the mid-section - measure twice, think about it! then cut! My track that the boards slide into is 3/4". Did the math after consult with US Plastics tech people and decided to rout the edge of the material that slides into the track slightly to make it less than 3/4" to allow for some thermal expansion.

I got the material from US Plastics. Mine was 3/4" X 24" X48" Polar White Seaboard UV Stabilized HDPE Sheet, P/N 46056. Cost in 2020 was $97.38. US Plastics was the supplier, VYCOM is the manufacturer of the material.

I also have the Zarcor doors which you can see the brackets so I can use them when I don't want the full boards in place.

Hope that helps.
 

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Jul 28, 2024
18
Catalina 25 Portland, OR
Thanks JRacer, super helpful! To confirm, you were able to get all three boards out of a single sheet of 24 x 48?
 

jssailem

SBO Weather and Forecasting Forum Jim & John
Oct 22, 2014
22,516
CAL 35 Cruiser #21 moored EVERETT WA
@max_sailing Run a tape measure from the middle of the Zarcor companionway doors to the bottom of the companion way opening. Then measure from the port to starboard side of the companionway opening. If 24x48 covers those measurments then yes. If not you'll need to get a bigger piece of board.

Note the purpose of the crib boards is to stop a wave (like the ones that are breaking over the Columbia River Bar) from washing over your stern and filling the cabin with water. You will want strong boards to prevent such an event. Such a boardign wave will fill your cockpit. It happens without notice, like the sudden appearance of a speeding freight train.:yikes:

It is not something to be taken lightly.
 

JRacer

.
Aug 9, 2011
1,355
Beneteau 310 Cheney KS (Wichita)
Thanks JRacer, super helpful! To confirm, you were able to get all three boards out of a single sheet of 24 x 48?
I did two boards, horizontal seam at about the mid point. Yes, even with the mistake of having to redo the top section, I had plenty of material. If you really enlarge the photo, you can barely see the seam about the mid-point of the bottom vent cap. Just measure the widest part X the tallest part of your opening including the inside of the tracks. If that is less than 24 X 48 the 24 X 48 board should suffice.
 
Jul 28, 2024
18
Catalina 25 Portland, OR
Thanks for the words of wisdom @jssailem. I was thinking more along the lines of compromising on the aesthetics. Good reminder not to compromise on the strength.
 
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JRacer

.
Aug 9, 2011
1,355
Beneteau 310 Cheney KS (Wichita)
I just now realized that you meant your Beneteau First 310, not your “first” of many Catalina 310’s :facepalm:
That is correct. I also did the same thing on the J24 when I had that. "Never" have to replace them!
 
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Jun 2, 2004
3,475
Hunter 23.5 Fort Walton Yacht Club, Florida
Signboard

Check with a local sign maker. They may have a composite material that works really well and is much lighter than starboard.
 
Aug 29, 2016
135
Catalina 2004 310 (Hull #250) BC
I went super simple: Home Depot - used a sheet of corrugated roofing sheet. Cheap. Strong and light. The corrugation takes up the thickness of the companionway channel. Cut it with shears.
 

jssailem

SBO Weather and Forecasting Forum Jim & John
Oct 22, 2014
22,516
CAL 35 Cruiser #21 moored EVERETT WA
a sheet of corrugated roofing sheet
Entertaining idea.

That is enough to hold back the ocean waves from getting to your inner sanctum?
 
Aug 29, 2016
135
Catalina 2004 310 (Hull #250) BC
Entertaining idea.

That is enough to hold back the ocean waves from getting to your inner sanctum?
Even better in some ways because the hatch boards have four or five teak sections that potentially allow water in, whereas the roofing sheet has a one piece construction. By the way, you can use two sheets overlapped - that's what I do sometimes to add stiffness. The corrugation allows different position options as the two layers can lock together. The sheets can also be rolled and stored away, if need be.

1738769808655.jpeg
 
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DArcy

.
Feb 11, 2017
1,762
Islander Freeport 36 Ottawa
My previous boat had acrylic (Plexiglass) hatch boards. I liked the look, they were smoked grey so had some privacy but allowed light through. Plexiglass is stronger than King Starboard and comparable to plywood. It is easy to work using woodworking tools. Probably more expensive than plywood, but might be cheaper than Starboard.

The hatch boards on that boat were in two pieces, there was a strip bonded to the top of the back of the lower board forming the lip.
 
Jul 28, 2024
18
Catalina 25 Portland, OR
Even better in some ways because the hatch boards have four or five teak sections that potentially allow water in, whereas the roofing sheet has a one piece construction. By the way, you can use two sheets overlapped - that's what I do sometimes to add stiffness. The corrugation allows different position options as the two layers can lock together. The sheets can also be rolled and stored away, if need be.

View attachment 229644
Can I borrow the old crib boards I see laying off to the side ;)?
 

Joe

.
Jun 1, 2004
8,137
Catalina 27 Mission Bay, San Diego
Since you're going offshore with the opportunity to experience some challenging conditions, I have three or four suggestions for your consideration.
When you build these boards, they should not wobble or rattle in the hatch frame's channel. So.... if you angle cut, rather than notch cut, the boards, the top could possibly pinch itself into the lower board. A proper thickness should prevent this happening so the boards have very little play. If you go with the angle cut, making it shallow, maybe 10 degrees, but remember the bulkhead sits at an angle, that should be added into the cut angle and you'll end up with a deeper angle than you expect... another reason to opt for the notch cut, which is easily made with a few passes on your table saw.

For a secure offshore set up, it should be possible to lock each board in position from both sides. Not at the same time, but so you can lock them in place from either inside or out. Simple sliding latches, a long rod, etc. there are a couple of designs you can use. If the boards are locked in place, a knockdown will present less risk of flooding... if they are attached with a snap on cable or pendant they won't disappear if you capsize... I know this sounds alarming, but it isn't going to be that much more work to build this feature into the boards.

This thought has reminded me of the importance of the "bridge deck" designed into most offshore vessels. A bridge deck protects the water from sloshing into the cabin should the boat get pooped.... so...... you might consider making a gasket or seal for the lower board. Oh...... that's another reason to go with three boards instead of two. The boards on my little Catalina 27 are cut so the bottom of the three is exactly the height of the cockpit benches. This allows you to leave the bottom board in place and still get into the cabin or maintain good ventilation in hot weather. Since you want this board to act as a "bridge deck board" it will fit somewhat tighter, it's just easier to leave it in place should the conditions warrant.

Final thought, this is related to the previous one, where we're concerned about getting pooped or a rogue wave slapping you at night and filling the cockpit with water. I suggest you examine your cockpit drains..... at the very least, make sure they are clear and flushed. If you have those little grates over the drain holes you might consider removing them....or at least be aware how easily they can get blocked up. If you are really into it you might even want to install another set of drains.....or enlarge the existing ones... the idea is to evacuate the water in the cockpit as fast as possible.

Years ago, I read this book about small boats that had made circumnavigations. There was a guy that did it in a Cat27 ( I can't imagine an intelligent person doing that, btw) and there was a list of upgrades he made to make the boat somewhat safer for going off shore. At the top of the list was enlarging the cockpit scuppers....because Catalina's, in general, have large cockpits....'cause they're coastal ya know and people like to entertain........... I always remembered that point... so easy to do... yet.... why do the designers not consider it??????

Okay, have fun.
 
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