Cabin Sole Refinishing - installing floor hardware

Since returning to Florida, the majority of our efforts have gone towards completing the installation of Lonwood Marine Flooring on the cabin sole.  Save for re-installing the trim we have completed the galley & salon area.

Looking aft at new flooring in the salon & galley. 

This section of flooring had two weeks of dry time while we traveled to North Carolina.  Over the past couple days, I  trimmed the edges at the floorboard joints and installed the floor hardware.

Floor hardware?  Well this includes a recessed finger handle for each floor board and a strike plate for the bulkhead mounted table leg (both visible center, right in image above.) 

After finding the ideal location for each floor board's handle, I began the installation by using a 1 1/8" paddle bit to auger out a depression for the center of the handle.  The circular center is the deepest portion of the handle. While the large diameter hole is only partial depth, the I did ensure the paddle bit's center point did pierced the backside of the flooring. The small hole will prevent water from pooling under the handle. 

I began the floorboard handle installation by drilling out the center section.

With the center drilled, I then used calipers to mark the location of the hinge portion of the handle.  The hinge is the second deepest portion of the handle.  A razor knife and chisle were used to excavate the flooring material. 

using the handle to mark off material to be removed.

At this stage the base plate of the handle rest flush on the new flooring and could be used to trace out the remaining area to be removed.  The thickness of the new flooring nearly matched the thickness of the handle plate so in most areas only the new flooring was removed to recess the baseplate.

Once the handle fit neatly into the recess, four #8 counter sink screws hold it in place.

Previously only two of C'est la Vie's five removable floor boards contained  recessed handles.  We plan to install a handle in each section.

With the area aft of the main bulkhead complete, we are onto making templates and cutting flooring for the forward area.

back to creating templates and cutting flooring.

  
 We plan to glue the remaining flooring down tomorrow morning.

a short hiatus - a.k.a. off to opposite ends of North Carolina

One of the difficulties of sharing personal information on the internet is you never know who is out there consuming.  So rather than advertise our absence from Sunset Island and a loney C'est la Vie awaiting at the dock for our return, I simply remained silent about our two week trip to NC. 

After 9 years of calling Sunset Island home, we are now moving out.  

Sunset Island Lodge and the Sinker boarded up for the summer season

Our dream to live aboard C'est la Vie for a couple years is becoming a reality,  but some of the steps along the way are difficult. Surprised by the amount of stuff we have collected and saddened at the thought of leaving this amazing island on the cusp of Florida's Ten Thousands Islands, packing up belongings that will remain on land during our trip proved both physically and mentally taxing.

Wow that is way more stuff than we envisioned packing up.

Anne departed a couple days before I did.  After a deposit at our storage unit.  She went to the mountains to open up the Outward Bound School's Cedar Rock Basecamp Kitchen, welcome a new kitchen manager to the facility, and visit friends.  Her travels went well.  She reveled in the verdant tunnels of green that embrace the back roads during the western NC spring.  She enjoyed cooking for the staff in the spacious, industrial Cedar Rock Kitchen (I heard the fresh baked pretzels were to die for.)   She caught up with long time friends living in the Brevard and Asheville area.

My journey took me to the opposite end of North Carolina - the Outerbanks.   Like Anne, my first stop in NC was to visit my parents and make a hefty deposit in our rented storage unit.

Thanks to my father for helping us stuff our storage unit to full capacity.

After a couple days of classic Outward Bound logistics that involved sorting and transporting large quantities of outdoor gear over long distances I made my way back to the Atlantic Coast.  Upon my return my to Marshallberg, NC, I was greeted with a wonderful home cooked dinner from our friend Peggy.  I then set up Outward Bound's Outerbanks Basecamp and instructed a six day staff training.

practicing wet exit drills in the shadow of the Cape Lookout Lighthouse

A couple days of high winds and foul weather served to elevate the quality of the training.

paddling in 20+ knot winds off Bells Island

I enjoyed my time in the OBX and appreciate the NCOBS staff for contributing to the success of the training.  More images of from the training are available on line... OBX Staff Training - Spring 2013 

Anne and I reunited in Beaufort, NC on April 10th.  We spent one night catching up with local friends at our favorite Friday night hangout - Aqua, before renting a car and returning to Sunset Island, FL.  

The plan now is to complete a few outstanding boat projects... Cabin Sole Installation; Solar Panel Installation, Re-install deck hardware on the freshly painted cabin trunk, etc. 

Refinsihing the Cabin Sole with Lonseal

When does a project actually begin?  

I maintain a project list in the form a a spreadsheet.  The projects are assigned a 1 through 5 priority, with 1 being the most urgent need.  Refinishing the cabin sole rose a number one priority after enduring rough crossing from Wilmington, NC to Green Turtle, Abacos in which the varnished sole became wet and resembled a ice skating rink (see Happiest Thanksgivings To All.)  Did the project begin when it rose to the top of the list?

Last spring on our drive north to drop our car in Beaufort, we stopped by Seafarer Marine to pick up Lonseal Flooring and adhesive.  I felt sure that during hurricane season while hauled out in Beaufort I would get the new sole installed, but then the engine haul out consumed my fall. (see Success C'est la Vie's Engine Is Out.)  Did the project begin when we purchased the materials?

In February of this year I announced to the world on this blog that the cabin sole refinishing project was underway (see Refinishing C'est la Vie's Cabin Sole.).  I pulled the flooring out of storage, removed the tiny quarter round trim, and ripped up some of the old veneer.  In the process I realized the interior brightwork had lost its luster.  Recognizing the mess that sanding all the interior wood would create, I put the sole project on hold.  Did the project begin when I shared it with the world?

I can now stand before you all, two and a half years after the project rose to a top priority, one year after purchasing the materials, and over one month after a false start and confirm that the cabin sole project is underway.

The Lonseal Flooring is a textured, flexible, mat approximately 1/8" thick.

Lonseal Flooring laid out atop a 4'x8' work bench

Seafarer sold it by the linear foot off a 6 foot wide roll.  We purchased 8 feet (48 square feet) and a gallon of the 2 part Lonseal adhesive #300. 

Initially I planned to create cardboard templates of the cabin sole, but some of the complex joints proved difficult to capture in cardboard.  Based on past successes with plastic sheeting as templates when sewing, I switched materials. 

using plastic sheeting  to trace out cabin sole sections

The plastic proved ideal for capturing the shape of the floor sections, but less effective than cardboard to test fitting all the pieces. No problem... I transferred the plastic patterns to the cardboard.

The cardboard provided stiff templates that I could piece together for test fitting on C'est la Vie's sole.

test fitting cardboard templates in C'est la Vie

Once satisfied with the fit, I removed the center panels from the boat and together with the cardboard reconstructed a portion of C'est la Vie's cabin sole  atop the Loseal.

Laying it out in this manner allowed me to ensure the holly strips would line up well along the length of the galley and salon.  The material proved relatively easy to cut with a razor knife and straight edge. 

using a razor knife an straight edge to cut the Lonseal Flooring

The curves were cut free hand.   Some of the shapes. like the one below that fits around the galley sinks, proved quite whimsical.

I chose to begin the glueing with three of C'est la Vie's removable floor panels.  This allowed me to work with the unfamiliar two part Lonseal adhesive #300 in a more ergonomic environment than the hull of the boat.   

gluing the new flooring down (pssst:  don't tell Anne I used her rolling pin.)

Albeit sticky and slimy at the same time the glue proved easy with which to work.  It must be troweled on, but has a long open working time.  The total dry time is 72 hours.  Checking the work this morning 14 hours after application, I am pleased with the results.  

To Be Continued....





  

Busy Week on C'est la Vie and Sunset Island

Last week was a blur of activity all of which is drawing us closer to casting off and cruising for a couple years. 

We are in the process of moving out/off of Sunset Island, our residence for the last 8 winters and for all practical purposes our home base.  My parents drove down from North Carolina to assist with the transition and to shuttle some of our belongings northward (Thank you!).  

C'est la Vie also drew much of our attention last week.  Every morning began with a couple hours of sanding on the cabin truck.  The week started with 80 grit paper on fairing filler and ended with 400 grit paper on Interlux Brightsides.
  

One coat of Interlux PreKote on the cabin trunk.  The unpainted areas on top will be covered with Kiwi-Grip non-skid.

Completing sanding in the morning allowed us to apply primer / paint midday when our tarps cast the entire cabin in shadow. 

The companionway slider and turtle with two coats of Brightside Paint.  The center of the turtle is primed for Kiwi-Grip.

We removed  turtle & companionway slider, and worked on them inside.  These pieces were one day ahead of the boat (i.e. primer, paint, and non-skid went one on day before the boat.)  This allowed us to become more familiar with the products prior to moving onto C'est la Vie. 

Neither of us had previously worked with Kiwi Grip so the ability to practice on smaller areas prior to tackling the top of the cabin was particularly helpful.

Anne spreading Kiwi Grip on the cabin top.  I would soon follow with a textured roller.

The Kiwi Grip proved to be a pleasure with which to work.  It goes on in one coat, is forgiving, dries quickly, and cleans up with warm water.  Compared to the process of painting with the Interlux or Awlgrip Products - multiple coats, lots of sanding, proprietary chemicals to thin / clean, and long overcoat times  the Kiwi Grip is a dream.  I know we are comparing apples to oranges, but  Anne and I jokingly discussed simply painting everything above the toe rail with Kiwi Grip.  Now what remains to be seen is the durability of the Kiwi Grip.

Painting completed on the cabin trunk.  Next up are the decks.

Nearly two weeks ago, 13 days, we began this project by stripping hardware off the deck.  The handrails, turtle, dodger, etc. still need to be re-installed, but it is wonderful to be able to step back this morning and feel a sense of accomplishment.

C'est la Vie shows off her new topsides paint and solar vent fan.

More images and details about this project are available in our photo album: Painting Cabin Trunk - Spring 2013

Our efforts during the week were not limited to painting or packing.  During the drying times we installed the new solar powered vent fan in the head, continued work re-finishing the cabin sole, and installed the PV charge controller in the electrical panel.   I will likely pen additional posts about these installations, but images and details are now available in photo albums...

Solar Vent Fan Install - Spring 2013
Refinishing the Cabin Sole - Winter 2013
Solar Power Install - Spring 2013

Back to work...

  

Installation versus Extraction

Despite the fact that we are now a day behind where I dreamed we would be on the painting project, it feels like we have turned the metaphorical corner.  We are no longer extracting objects from the boat - the gallows, the turtle, the companionway cover, paint, gel-coat, etc.  Yesterday we began re-installing objects on the boat...

Anne added the final coat of paint to the area under the turtle (to save some time & expense we used house paint on this unseen portion of the decks.)

Quite the painting pants...  An homage to the recently deceased Lily Pulitzer.

We are into our second round of adding fairing filler to the cabin trunk.  Fairing the cabin trunk has proven more time consuming than I anticipated.

The red circles identify areas requiring an application of fairing filler.

We applied the initial coat of primer to the turtle and the companion way cover.

Perhaps the day's greatest signal of progress was the installation of the refinished boom gallows crosspiece.

The gallows refinished with 3 coats of epoxy and 8 coats of Bristol Finish

With the  boom resting on the gallows we can drop the topping lift and Dutchman furling system.  This will allow us to more easily set up shade tarps over cabin trunk when painting.

The return of the gallows will also allow us to begin work on fabricating a new piece of fiberglass re-enforced paneling (FRP) for the bimini.  Once the bimini returns then we can begin the installation of the new solar panels.

progress, progress, progress...

Rain Delay #1

Anticipating showers and thunder storms, I got an early start on sanding the deck.  Dawn revealed an ominous sky.

Morning clouds over Sunset Island

In about two and a half hours of sanding I completed half the cabin trunk.  Then the sky opened up.

A good rinse after two and half hours of sanding.

What I accomplished looks good, but we definitely have another round of fairing in our future.  Most of the additional fairing is at the junction of the cabin trunk and the deck.    

Now I'm headed back to the shop to sand down the gallows cross piece in preparation for a final coat of Bristol Finish.

Juggling Projects and Watching the Weather

The stable weather of the last week has eroded over the past 48 hours.  While we have only had one thunderstorm roll through the outlook has slowed our progress on repainting the deck.  

Anne cleaning tools after adding fairing filler to the cabin top.

 We did complete adding fairing filler to areas on the cabin trunk this afternoon.  Weather permitting tomorrow we will unleash the sanders.  We hope to have the area ready for primer by Monday.

The gallows cross piece now 3 coats of epoxy & 6 coats of Bristol Finish applied.

I continue to build up the finish on the boom gallows cross piece and other bits of bright work.  I'm going for 3 coats of epoxy and 8 coats of bristol finish on the cross piece.  At my current pace it should be ready to re-install on Sunday.  

Six coats of finish and a shiny hinge doth a rejuvenated  table make.

I also completed refinishing our table and installed a new hinge.  

Progress, Progress, Progress...

A Very Filling Day

Anne taping off areas to be filled.  I followed behind with thicken epoxy. 

Yesterday we teamed up to filled the areas ground out on the cabin trunk.  In the morning we applied epoxy thicken to the consistency of mayo to fill.  The day was warm, windy, and sunny so the epoxy cured quickly.  Late in the  afternoon I returned and used an orbital sander with 80 grit paper to fair out the epoxy.

C'est la Vie in leopard print/

What did I do with ilde hands at midday?   Brightwork of course....