O'day 39 project boat
- Thread starter Panta Rei
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Just a tech question. Are you epoxy coating the underside of the countertop and edges? This was the technique I used throughout YOT. Every stick of framing, edge and underside was coated to prevent any chance of moisture wicking into the wood. It added quite a bit of work but the peace of mind was worth it. I even went so far as to coat the backsides of the galley woodwork with only the visible faces stained and urethaned.
Epoxy encapsulation
Great question Joe. I completely agree with your encapsulation strategy. You are creating something that can no longer be considered just an O'day. They, like many many other builders had to make choices since they were offering a sailboat intended for the mass market. The fact that we are all here talking about our boats 25 to 30 years later tells you that they did a very good value engineering job. But for us who have dismantled much of the boat, we must take this opportunity to do what O'day could not. Removing and sealing off core as we re-bed deck hardware, redesign headline panels (coming soon). Some upgrades like LED lighting because technology changes. And of course epoxying all the wood, because we have the chance and we know it's the right thing to do.
Now specifically the counter top, No, I will not be coating it even though I know the top will someday de-laminate. I'm no even using Marine grade plywood. My reasoning is this, De-laminating alone does not affect the counter top. Mine was completely de-laminated but it was not until I pulled up the sink I could tell. Being de-laminated saved me from tearing the complete cabinet apart. The Ice box throws a wrench in the way the cabinet and counter top are put together as tcwaltz explained. I want to leave behind the same possibly of peeling up the plywood one layer at a time. I will reassemble using tcwaltz's instructions and will protect the spot where water can come around the laminate into the plywood. But that is all. As for the cabinetry. YES, it's very valuable and would be very difficult to replace. That gets at least one coat of varnish on all sides. It is solid teak. I'm comfortable with varnishing it. Anything near the bilge gets epoxy.
This brings to mind one topic that I will (and I hope you will too) completely address when we get these boats all put together. O'day Quality: What I have seen, I give O'day High marks. Each peice of cabinetry is press fit then secured by screws. Its offen very difficult to remove some of the cabinetry for this reason. Sure, the hull tabs are screwed (not through bolted)to the bulkheads but has any of us found this to be a weak spot? What I see in my boat is Value engineering. The boats were built for the market intended. Now Joe and I can re-evaluate O'day's value engineering in a new light. With a different purpose, we will reach different conclusions.
Great question Joe. I completely agree with your encapsulation strategy. You are creating something that can no longer be considered just an O'day. They, like many many other builders had to make choices since they were offering a sailboat intended for the mass market. The fact that we are all here talking about our boats 25 to 30 years later tells you that they did a very good value engineering job. But for us who have dismantled much of the boat, we must take this opportunity to do what O'day could not. Removing and sealing off core as we re-bed deck hardware, redesign headline panels (coming soon). Some upgrades like LED lighting because technology changes. And of course epoxying all the wood, because we have the chance and we know it's the right thing to do.
Now specifically the counter top, No, I will not be coating it even though I know the top will someday de-laminate. I'm no even using Marine grade plywood. My reasoning is this, De-laminating alone does not affect the counter top. Mine was completely de-laminated but it was not until I pulled up the sink I could tell. Being de-laminated saved me from tearing the complete cabinet apart. The Ice box throws a wrench in the way the cabinet and counter top are put together as tcwaltz explained. I want to leave behind the same possibly of peeling up the plywood one layer at a time. I will reassemble using tcwaltz's instructions and will protect the spot where water can come around the laminate into the plywood. But that is all. As for the cabinetry. YES, it's very valuable and would be very difficult to replace. That gets at least one coat of varnish on all sides. It is solid teak. I'm comfortable with varnishing it. Anything near the bilge gets epoxy.
This brings to mind one topic that I will (and I hope you will too) completely address when we get these boats all put together. O'day Quality: What I have seen, I give O'day High marks. Each peice of cabinetry is press fit then secured by screws. Its offen very difficult to remove some of the cabinetry for this reason. Sure, the hull tabs are screwed (not through bolted)to the bulkheads but has any of us found this to be a weak spot? What I see in my boat is Value engineering. The boats were built for the market intended. Now Joe and I can re-evaluate O'day's value engineering in a new light. With a different purpose, we will reach different conclusions.
I completely agree with you on the Oday value Todd. These boats have stood the test of time and remain a formidable presence in sailboats. Having worked in a marina in high school and again after the recession of 1982 I was able to see a variety of boats that were experiencing severe problems with their construction. In the age of disposable everything Oday ran countercultural and built a product that would remain operational for decades. Most of my work with YOT was centered around technology advances rather than reinventing the wheel so to speak. As some may recall WEST Systems was an abreviation for Wood Epoxy Saturation Technique. One local boat 'Wild Card' was built at Sill's Marine in Sodus, NY using this technique. It did quite well in the club races with it's gleaming mahogany strip hull. My elder son is refering to this as the heirloom boat. I certainly hope so. It would be nice to have given this boat another 30 or so years.
A layer of verticle grade laminate on the bottom of the top will prevent alot of moisture damage
icebox top insulation
I will also seal the insert with butyl rubber.
Click on the photos for close-ups.
Your point about the counter top is well taken. I designed the inserts so seal off the counter top. The inserts have a 2" lip that sits on the 2" lip of the icebox.
I will also seal the insert with butyl rubber.
Click on the photos for close-ups.
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Baking the boat in a desert.
I've read that the best way to dry out a boat is to put it in the desert. My little town between Madison and Milwaukee has not seen significant rain for many many weeks. Outdoor grilling , and even smoking is not permitted outdoors. Most grass has turned to powder.
Perfect conditions for drying out my boat. I'm glad I have all the wood varnished.
The force ten 3 burner stove showed up at the local West marine. The thing is spectacular. Everything polished stainless.(even the burners) The wife will be afraid to cook on it.
I will be prepping for the install later this week. I'm traveling a lot for the next week. I may not get to it for a while.
Finally starting to feel like the boat is being put together not taken apart.
Click on the photos
I've read that the best way to dry out a boat is to put it in the desert. My little town between Madison and Milwaukee has not seen significant rain for many many weeks. Outdoor grilling , and even smoking is not permitted outdoors. Most grass has turned to powder.
Perfect conditions for drying out my boat. I'm glad I have all the wood varnished.
The force ten 3 burner stove showed up at the local West marine. The thing is spectacular. Everything polished stainless.(even the burners) The wife will be afraid to cook on it.
I will be prepping for the install later this week. I'm traveling a lot for the next week. I may not get to it for a while.
Finally starting to feel like the boat is being put together not taken apart.
Click on the photos
Attachments
Polishing the sink really made a difference.
Took a week off to do some Business travel.
This project will kick into high gear in August. Starting to ramp it up now.
We checked out a few marinas Saturday to launch the boat. This is proving to be a bit more challenging than I expected. We are looking at Marinas on the west side of Lake Michigan North of the Wisconsin Illinois line and south of Green Bay. I want full repair service and a travel lift or equivalent. Suggestions would be greatly appreciated.
The Galley is nearly complete. Sink is polished and re installed. New faucet, counter top, added insulation to the Icebox. I will not be replacing the two hand pumps. One that pumps out the icebox and the other for sea water. They no longer match the polished stainless of the sink and range. I'll likely go with electric pumps.
Polishing the sink proved to have the highest impact of anything I have done so far. It was a huge improvement. Two hours of work to do the polishing. I had expert advice which is needed. Polishing to a mirror finish is an art more than science. Purchasing a new sink may be the best option for most. Now that I have seen the results , i would spend the $600 for a new polished sink with out hesitation.
Photos later today once I hang the range.
Clean-up is in progress. The floor of the boat is loaded with bottom paint that got in when the hull was blasted and drips of varnish. Varnish is easy to remove with MEK getting all the bottom paint dust is getting to be a lot of work.
My largest mistake to date was not sealing up the boat before blasting the bottom. I had a tarp on the deck. It acted as a deflector catching and grit and dust that was shot upward and redirecting it across the deck and into the hatches. Big mess.
Took a week off to do some Business travel.
This project will kick into high gear in August. Starting to ramp it up now.
We checked out a few marinas Saturday to launch the boat. This is proving to be a bit more challenging than I expected. We are looking at Marinas on the west side of Lake Michigan North of the Wisconsin Illinois line and south of Green Bay. I want full repair service and a travel lift or equivalent. Suggestions would be greatly appreciated.
The Galley is nearly complete. Sink is polished and re installed. New faucet, counter top, added insulation to the Icebox. I will not be replacing the two hand pumps. One that pumps out the icebox and the other for sea water. They no longer match the polished stainless of the sink and range. I'll likely go with electric pumps.
Polishing the sink proved to have the highest impact of anything I have done so far. It was a huge improvement. Two hours of work to do the polishing. I had expert advice which is needed. Polishing to a mirror finish is an art more than science. Purchasing a new sink may be the best option for most. Now that I have seen the results , i would spend the $600 for a new polished sink with out hesitation.
Photos later today once I hang the range.
Clean-up is in progress. The floor of the boat is loaded with bottom paint that got in when the hull was blasted and drips of varnish. Varnish is easy to remove with MEK getting all the bottom paint dust is getting to be a lot of work.
My largest mistake to date was not sealing up the boat before blasting the bottom. I had a tarp on the deck. It acted as a deflector catching and grit and dust that was shot upward and redirecting it across the deck and into the hatches. Big mess.
Galley nearly complete
Polishing the sink and upgrading the range to a three burner (all mirror finished) made a huge difference.
I have not decided on the color for the metal corner fiddles. I'll decide tomorrow and complete the galley and move on.
Polishing the sink and upgrading the range to a three burner (all mirror finished) made a huge difference.
I have not decided on the color for the metal corner fiddles. I'll decide tomorrow and complete the galley and move on.
Attachments
Putting the boat in the water this fall
Thanks goes out to "25 years later" Joe for the great source for foam (Foam Factory Clinton MI) Joe sent me the link several times. This time I ordered what I needed immediately. $130 for both settees (seats and backs).
I think I have a great source for vinyl. Rockford Supply near Minneapolis. I will be up there Monday and hopefully pick up the headlined and the settee material.
I pulled the trigger and decided to put the boat in the water this year. $1000 deposit will give me a slip for this year with the $1000 going towards next year's slip fee. I wanted to take my time like Joe but I need the get the boat in the water to see how the engine and transition checks out. Any major repairs can be done during the winter so I'll be ready for spring.
There is a lot of work yet to be done. I plan to get up early and work a few hours each day. Nothing to challenging yet to do. Just work.
I'll put the refrigeration in the second ice box next spring. Electronics will come in a year or two just before I head out towards the salt water. No need to put them in now. I will mount the windlass while I have the stainless fabricators a few feet away.
Bottom paint
Deck paint for the non-skid
clean up the smooth gelcoat on the deck and apply polyglow to it.
Lots and lots of odds and ends
Thanks goes out to "25 years later" Joe for the great source for foam (Foam Factory Clinton MI) Joe sent me the link several times. This time I ordered what I needed immediately. $130 for both settees (seats and backs).
I think I have a great source for vinyl. Rockford Supply near Minneapolis. I will be up there Monday and hopefully pick up the headlined and the settee material.
I pulled the trigger and decided to put the boat in the water this year. $1000 deposit will give me a slip for this year with the $1000 going towards next year's slip fee. I wanted to take my time like Joe but I need the get the boat in the water to see how the engine and transition checks out. Any major repairs can be done during the winter so I'll be ready for spring.
There is a lot of work yet to be done. I plan to get up early and work a few hours each day. Nothing to challenging yet to do. Just work.
I'll put the refrigeration in the second ice box next spring. Electronics will come in a year or two just before I head out towards the salt water. No need to put them in now. I will mount the windlass while I have the stainless fabricators a few feet away.
Bottom paint
Deck paint for the non-skid
clean up the smooth gelcoat on the deck and apply polyglow to it.
Lots and lots of odds and ends
The punch list is daunting. For the first time, I'm a bit intimidated by the number of systems on this boat.
I just spent the day finishing the icebox on the port side and touching up wood work. I added two Finspray pumps to the galley. One to pump out the port icebox and the other for Seawater. Checking off the icebox took a lot of work. Adding the pump, routing the hose and checking for leaks (both the box and the hose) I have yet to build shelving for the icebox but that may wait until the winter.
Started cleaning up the starboard side Icebox. It had refrigeration so it has a good size hole. It will be a project. I Will post pictures soon hoping for suggestions.
Ordered the Windlass. It's a horizontal windlass. The anchor locker lid has a bulge for a vertical windlass but I like the Powerwinch 41 price and performance. We will start doing engineering work once we see the windlass and see how it fits (or doesn't).http://www.powerwinch.com/powerwinch/controller?action=product&c=3&p=19
Next post I will list the ground tackle .
I just spent the day finishing the icebox on the port side and touching up wood work. I added two Finspray pumps to the galley. One to pump out the port icebox and the other for Seawater. Checking off the icebox took a lot of work. Adding the pump, routing the hose and checking for leaks (both the box and the hose) I have yet to build shelving for the icebox but that may wait until the winter.
Started cleaning up the starboard side Icebox. It had refrigeration so it has a good size hole. It will be a project. I Will post pictures soon hoping for suggestions.
Ordered the Windlass. It's a horizontal windlass. The anchor locker lid has a bulge for a vertical windlass but I like the Powerwinch 41 price and performance. We will start doing engineering work once we see the windlass and see how it fits (or doesn't).http://www.powerwinch.com/powerwinch/controller?action=product&c=3&p=19
Next post I will list the ground tackle .
Foam and Vinyl
No kidding Jibes. I was a bit surprised that only plastic pumps would show up when I shopped on line for the galley pumps. It was only after I googled Finspray pumps did a website show up that sold them. I also had a finspray pump with a plastic base but I decided to go with a matching pair. I think this pump is a function match for the chromed brass pump so I will keep it for spare parts.
Joe, The foam arrived. Good stuff Great price. Thanks!!!
I picked up the headliner and vinyl for the seating in Minneapolis yesterday. Rochford (not Rockford) supply. Great prices.. $84 for the headliner and $84 for the seats. We purchase 7 yards of each. one extra yard for each just in case.
I cut new panels for the headliner and hope to trial fit them today.
No kidding Jibes. I was a bit surprised that only plastic pumps would show up when I shopped on line for the galley pumps. It was only after I googled Finspray pumps did a website show up that sold them. I also had a finspray pump with a plastic base but I decided to go with a matching pair. I think this pump is a function match for the chromed brass pump so I will keep it for spare parts.
Joe, The foam arrived. Good stuff Great price. Thanks!!!
I picked up the headliner and vinyl for the seating in Minneapolis yesterday. Rochford (not Rockford) supply. Great prices.. $84 for the headliner and $84 for the seats. We purchase 7 yards of each. one extra yard for each just in case.
I cut new panels for the headliner and hope to trial fit them today.
Hopefully you had a clear area when you cut the wrapping. I had lamps and various stuff sailing across the living room when it expanded. I used a cheap electric knife from walmart to cut the shapes and trimmed with scissors.
I wonder if they fold sails????
I don't know how they do it. see photos. Two little boxes.The foam sheets are 8" long!!
Attachments
Time to get serious
My plan was to finish things up in August. Wednesday the project kicked into high gear. Tuesday, I lined up all the projects I needed the shop to do. I arrived an hour late Wednesday morning and many were already completed. The Stainless shop (Aggressive Metals of Lake mills Wi)was waiting for a big order to be finalized so it was a perfect time to pick up my work.
Anchor was blasted primed with zinc rich primer and top coated with bright silver.
Ladder mounted on the swim platform.
anchor pulpit removed and welded.
One stantion removed and inspected (see photo) corrosion and a crack. A lost cause.
Stainless trim added to Companion way door frame.
Bow rails removed straightened, welded and polished.
These guys are masters.
I don't have a lot of time now but I hope to post soon with a final punch list.
Final projects include
Headliner
upholstery
windlass installation
My plan was to finish things up in August. Wednesday the project kicked into high gear. Tuesday, I lined up all the projects I needed the shop to do. I arrived an hour late Wednesday morning and many were already completed. The Stainless shop (Aggressive Metals of Lake mills Wi)was waiting for a big order to be finalized so it was a perfect time to pick up my work.
Anchor was blasted primed with zinc rich primer and top coated with bright silver.
Ladder mounted on the swim platform.
anchor pulpit removed and welded.
One stantion removed and inspected (see photo) corrosion and a crack. A lost cause.
Stainless trim added to Companion way door frame.
Bow rails removed straightened, welded and polished.
These guys are masters.
I don't have a lot of time now but I hope to post soon with a final punch list.
Final projects include
Headliner
upholstery
windlass installation
Attachments
headliner
My punch list has over 30 items on it. I have no choice but to take much of this month off to complete the boat.
Now doing the headliner. I stumbled upon a great product from Home depot. It's basically double foil sided bubble wrap. Installation is a snap. Used the cheapest contact adhesive I could get my hands on. The stuff weighs no more than bubble wrap but it blocks 96 % of the radiant heat. I could feel the difference as I installed it. The main cabin is much cooler than the cabins at each end that do not have the foil. Low cost as well.
I'm using velcro to hold the headliner panels up. Works great.
Note the box fan. Could not do the project without it. Installing the inverter first was a stroke of luck.
This boat is now done dry.
My punch list has over 30 items on it. I have no choice but to take much of this month off to complete the boat.
Now doing the headliner. I stumbled upon a great product from Home depot. It's basically double foil sided bubble wrap. Installation is a snap. Used the cheapest contact adhesive I could get my hands on. The stuff weighs no more than bubble wrap but it blocks 96 % of the radiant heat. I could feel the difference as I installed it. The main cabin is much cooler than the cabins at each end that do not have the foil. Low cost as well.
I'm using velcro to hold the headliner panels up. Works great.
Note the box fan. Could not do the project without it. Installing the inverter first was a stroke of luck.
This boat is now done dry.
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