My plans for this summer with BlackStar

[rtyszka]

My Plan of attack is this:

1. Finish cabin top
a. Large ports need replacement. (I found 2 manufactures that can make a solid alum frame with tempered glass or lexan windows) This would be a bolt in replacement and leaking would not be an issue. One of them even offered to make the windows open (sliding from smaller side), that option is a bit more money.
b. Take wood down and refinish sides
c. Replace, refurbish trim between wood and glass
d. re-bed hatches, replace plastic

2. Rebuild cockpit
This is huge, I am considering making cockpit a bit larger (reduce seat size ~4" each side, to increase walking area).
I am also going to make the cockpit floor and side walls out of fiberglass (one big box out of glass) only holes would be for wheel, emerg tiller and 2 drains. I am tossed between solid glass or laminated marine plywood. I was thinking of leaving seats wood. (I have brand new cushions that will be no good though)

The problem I have is how can I improve on the supports for the cockpit?

I have the full set of prints for the boat, and a ton of 1962 paperwork, if I modify the boat too much, I will loose some of that detail.

Richard

 

[jsmall]

I have the same question, as I too will have to rebuild my cockpit sole(which does not currently exist) How is the cockpit sole supposed to be supported. Perhaps someone could post some detailed drawings or photos.
Jimmy Small

 

[Dave Richardson]

Great news, Richard. I can tell that you are excited again about your Challenger. Super!
I'm just finishing my cockpit rebuild. Not the top part (seats, seatbacks, etc. are OK) but I started at the hull and worked up. I'm now re-designing the foreward panel, making it lower and at a better angle so we can see the instruments from the wheel.
I have tons of photos of Essay, as she was as as I've rebuilt her. My problem is getting them to anyone. My son set up a web site during our trip back from Texas and within about two weeks I can have him post some of them. (It is a PC-based site and I run a Mac) But I'd be happy to send you and Jimmy CDs of the whole lot, and answer any questions I can. Quetzalsailor already made a good point, after that post. I was about to use poplar for my sides. He brought up that it rots easily. Marine ply is a better choice.
To hint at an answer to your question, check my post of a couple of weeks ago on cockpit rebuilding.
If you are using the drawings from Alden, the ones they send out for $50, they actually mislead - based on what I found.
And be ready to put in lots of hours. But it is fun.
Dave

 

[TomY]

I will eventually do some work to my cockpit.

So this is good stuff to hear. When photos can be made available, that will be even better.

My feeling on my cockpit is that the plywood sole under the teak is simply too thin. Mine appears to be 1/2" marine ply. It may also be incorrectly oriented to the grain for strength. It's soft in the area around the wheel. A steel plate was added in the past when some work was done. This plate has the steering gear bolted to it. There is little you can do to brace from underneath(I've looked) with the steering quadrant needing its space.

I expect I will pull the whole sole by removing the fastening to the sides of the lockers. These mahogany pieces are in great shape and nicely joined in the corners(dove tailed).

Then I will rebuild using and adequate thickness of marine plywood, probably 3/4". That would require no center supports as it would carry the load across the span easily. I would do it in two pieces to keep the orientation of the majority grain running athwartship. Teak over that. I don't know all the details but this thread is helping me.

BTW, maybe it's because I sail in Maine but I like the manhole in the sole. It rarely gets that hot but the access is great for me, I'm not a big fan of getting into the cockpit lockers and working from there, this seems for me 6' 190lbs, "alittle" easier for working in this area.

 

[rtyszka]

Photo site (Free)

Dave, I posted my pictures on the Yahoo Photo site, it is free and will work fr PC and MAC. Not that hard to use or setup and no limit on amount of pictures.



http://login.yahoo.com/config/login?.sr ... s&.intl=us

 

[Dave Richardson]

Thanks for the tip, I’ll try the Yahoo site, and hope I can get some photos on it.
Tom may be right, that the 1/2 inch ply is too thin, but I replaced mine with 1/2 and it is much stronger than I expected, and much stronger than the original. I also added an extra support on each side, under the stacked 1" x 4 mahogany strips that run along the side. The ply fits between those long strips.
I haven’t found any dovetails, but the center block, which fits under the pedestal, is morticed into the cross pieces in front and behind it. This piece, actually two pieces with a slot in the fore end, beefs up that area. I also have a steel plate and a chunk of angle iron to increase strength. I have no idea what the original was.
I don’t have a manhole. Instead, someone build a heavy frame and attached a welded SS band around the edge. It was built up above the sole by 3/4 inch but I’m going to trying to get mine as close to the sole as I can. I'll try to seal it with beads of “something.”
I’m also at the point where I have to decide whether to build another entry hatch behind the wheel. Not sure yet about that one.
I also installed a small deck hatch on the stern. Thoughts on that in another post.

 

[TomY]

Great info from these projects you're doing Dave.

Pictures would help, I'm trying to imagine the construction of your cockpit. I suspect mine is mostly if not all original. There is no post under the binnacle but that would solve alot,, however, I don't see how it could fit with my steering arrangement.

I think you are right, my 1/2" plywood is losing strength but it does have to span the whole sole, new it was likely strong enough. I may get a brace in there somehow to elimenate some of the flex.

 

[rtyszka]

Cockpit

I was going to use 3/4 marine plywood for foor and 1/2" for sides. Glass the whole thing. The binacle mount is interesting, I am considerng installing a plate under the binacle to disperse the stress. I also was advised to build a seperate support structure for the steering hardware (not part of the cockpit floor structure.

I am in planning phase as the support stringers. I presently have 4 main supports and 4 smaller stringers all going to the hull. I draw this out as I go.

Tom made a good point on the manhole, I have mine still and may consider re-installing it, if I don't may have one available for anyone that may need one.