I've been planning this for a couple years and have finally started. Xmas is outside under tarps so I'm hoping to do almost all the work in a warm shop at home. I've watched the boat builders at Rockport Marine build some components outside of the hull to install finished. In fact they did a cockpit a while back that inspired me.
My plan is to remove everything from the base of the cockpit coamings-down. Once the entire old cockpit is removed, to the bottom of the coamings and the cabin back, I plan to install a ledge-all the way around. It will be screwed and epoxied -from below- into the coamings-cabin. That ledge will be L shaped and result in a 1" wide continuous flange on all four sides.
Upon installation of the new cockpit(this coming spring), the entire cockpit-bridge/seat deck - attached to the footwell- will be lowered onto the ledge(and the existing cockpit support structure below of 6 posts and 3 beams).
First step: Fit a template to the existing cockpit. Carefully scribed and fit out of 1/4" plywood. Support pine legs were placed and marked that upon assembly should be the exact shape I need to achieve to allow lowering the new cockpit onto the support below and flange.
Next was to build the footwell to the exact size of the existing well. I'll used 3/4" Marine plywood for the well and bridge/seat deck. Except for the well sides that will be glassed for painting, all horizontal planes will be strip decked in the traditional method. I'll resaw Ipe for the decking as Teak is too expensive.
Here's the cockpit well dry fit.
Here are the well pieces after adding a layer of fiberglass cloth and 2 fill coats of West system.
Finally(for now), the well sides sanded smooth(ready for paint-later) then reassembled with epoxy and screws. The sole is still dry and will be removed for - Ipe decking, fitting binnacle and pulleys, fitting bronze manhole and cover etc. before it's finally epoxied and fastened to the well for final installation(with all parts removed for weight).
The template assembled and placed on top. Now it's ready to begin fitting the bridgedeck/seat height deck structure with two cockpit lockers. I'm making some changes to things like locker lids in shape and size. Some I'm determining as I go. If you have any ideas, don't hesitate to chime in.
I tried to place these photos in their correct order but can't seem to make the uploader cooperate. They're in a reverse sequence, sorry.
My plan is to remove everything from the base of the cockpit coamings-down. Once the entire old cockpit is removed, to the bottom of the coamings and the cabin back, I plan to install a ledge-all the way around. It will be screwed and epoxied -from below- into the coamings-cabin. That ledge will be L shaped and result in a 1" wide continuous flange on all four sides.
Upon installation of the new cockpit(this coming spring), the entire cockpit-bridge/seat deck - attached to the footwell- will be lowered onto the ledge(and the existing cockpit support structure below of 6 posts and 3 beams).
First step: Fit a template to the existing cockpit. Carefully scribed and fit out of 1/4" plywood. Support pine legs were placed and marked that upon assembly should be the exact shape I need to achieve to allow lowering the new cockpit onto the support below and flange.
Next was to build the footwell to the exact size of the existing well. I'll used 3/4" Marine plywood for the well and bridge/seat deck. Except for the well sides that will be glassed for painting, all horizontal planes will be strip decked in the traditional method. I'll resaw Ipe for the decking as Teak is too expensive.
Here's the cockpit well dry fit.
Here are the well pieces after adding a layer of fiberglass cloth and 2 fill coats of West system.
Finally(for now), the well sides sanded smooth(ready for paint-later) then reassembled with epoxy and screws. The sole is still dry and will be removed for - Ipe decking, fitting binnacle and pulleys, fitting bronze manhole and cover etc. before it's finally epoxied and fastened to the well for final installation(with all parts removed for weight).
The template assembled and placed on top. Now it's ready to begin fitting the bridgedeck/seat height deck structure with two cockpit lockers. I'm making some changes to things like locker lids in shape and size. Some I'm determining as I go. If you have any ideas, don't hesitate to chime in.
I tried to place these photos in their correct order but can't seem to make the uploader cooperate. They're in a reverse sequence, sorry.
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