Building Our Cockpit Doors: The Exciting Start! (MJ Sailing - Ep 336)
One new project we have started though is our cockpit doors! Since we have no seating running along the sill of our cockpit, that entire space will eventually open up. Which means we need to make three separate doors to close it up at times. Two that will slide into pockets next to the cockpit seats, and one in the center which will lift up and latch to the cabin top.
Starting out with fresh sheets of 4x8 nidacore, Matt cuts them down to size, and we go about glassing both sides of them. Each side gets 0.75 oz of chop strand, and then two layers of a 45/45 biaxel.
For extra strength around the edges, Matt will be fitting in pieces made from layers of our unidirectional fiberglass. Matt firstly layers six sheets of our unidirectional, cuts them to size, then de-cores the edges around the doors and bonds in the pieces of cured unidirectional by using our TotalBoat structural putty.
In some other fun news, we get the chance to prime another area for the first time. Our cabin sides and the under the cabin top. Although the exterior sides of the cabin will be covered by glass or acrylic, we still wanted a fairly smooth surface for those to bond to. And since the underside of the cabin can be seen any time you're sitting on deck, yeah, we just want that to look good, haha.
Hopefully these steps will let us get into close up shape pretty soon! Once we move out of the tent and into the work yard, we can begin attaching the nose cones and stern to finally reach the full length of our catamaran!
We hope you enjoy!
MJ Sailing
From Arctic ice in a custom aluminum monohull to building a high-performance 42ft catamaran, Matt and Jessica of MJ Sailing define technical excellence.
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Today we delve into the exciting realm of building custom fiberglass cockpit doors for boats. The MJ Sailing team takes us through the meticulous process, from start to finish, as they create their unique boat doors. This comprehensive guide will walk you through each step with detailed explanations and demonstrations.
The Starting Point
With 1 and a half inch thick Nidore as the base material, the team showcases a plastic honeycomb interior, thermally bonded with a scrim fabric. This combination explains its density and strength. They plan to use two layers of 1708 fiberglass skin on either side.
Process Overview
To start, the team cuts down a 4×8 sheet of Nidore to the proper door size using a Bosch track saw for precision. Multiple layers of fiberglass are then layered and glassed together. A unidirectional fiberglass is used in key areas for added strength and rigidity.
Techniques & Tips
The alternative to their current approach would be making molds for each door, which could result in a better finish. However, given the uniqueness of each door and the effort required for molding, they opt for the more practical method.
Primers & Preparations
To ensure a smooth surface, layers of peel ply and cloth to soak up extra resin are used before vacuum bagging. Once the doors reach a rock-hard state, they’re cut down to final size, decor elements added with unidirectional fiberglass.
Challenges & Solutions
A challenge arises when attempting to reach areas above peaks. The team discusses possibly rolling on primer rather than spraying for more precise application. Additionally, planning for window placement and door hinges is key for a seamless finish.
Conclusion
With primer now applied to the exterior cabin sides, the team acknowledges there will be more work ahead, such as covering windows and finalizing door installations. Each step, from cutting and layering to decorating, brings them closer to achieving custom-fit cockpit doors.
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