The first steps down into the cabin of Hurry On were met with a squish. The cabin sole, which had spent a considerable time under water, had perished. The teak and holly veneer on marine plywood was peeling off to the point it was almost completely separated from the wood. The high traffic areas, like at the foot of the steps, sunk when trod upon. There was no bringing it back, it had to be replaced. Being the type of person who always seems to choose the method that involves the most sweat and cursing, I decided to try to replicate the method being researched by our friends at Joy in the Mooring and artfully carried out here.
Getting the old sole out was pretty simple, most of the screws keeping it down came out easily. Some of the screws were stripped, but luckily the wood surrounding them was rotten enough to pull it out and then take the screw out with vise grips.
Marine plywood has to be shipped to Cape Breton, but it can get get here the next day from Halifax. I got this piece of Douglas Fir marine ply from Sydney Millwork, for $116, this includes the shipping. I’ve never really worked with Douglas Fir before, and was therefore, not familiar with its fragile and splintery properties, which caused a few headaches down the road.
I was lucky that the sole of a C&C 27 MkV is a prefect rectangle. After cutting the pieces to match the original the only modifications were routing the bottom to give it a curved edge, and the four outside corners needed to be rounded slightly. I was considering making this from two pieces (the main floor and the bilge hatch) of wood instead of 4. Two pieces would certainly be stronger. But working with the large piece would be quite unwieldy . Also, I wasn’t 100% sure the large piece would fit in the boat. Finally, the original was in 4 pieces, and I’m sure they had their reasons.
The next step is stain the pieces. After sanding the entire surface, just to be safe, I used a wood conditioner which ensures a nice even coating to the stain with no blotches.
The stain went on evenly for both coats.
To get the teak and holly look, pieces of white wood are going to be set inside the plywood. When I got the plywood, I also ordered a long piece of poplar, this would serve as the strips. Using the poplar as a straight-edge, I ran the router with a 3/8″ bit down the lengths of the plywood at equal intervals.
The strips were cut out on a table saw, then refined with a planer. they were tested for fitting, then glued (plain old wood glue, as my old friend Gorilla Glue tends to expand, and I didn’t want any coming out, as there can be no sanding after this) and tamped. For the most part, the strips went in flush. There are a few areas where the are slightly elevated, but just barely noticeable when you pass your hand over it. Finally, 4 coats of clear varnish, with a light sanding with 320 grit between each coat.
Since there is much to do still, installing it will be one of the last jobs as to avoid the wear and tear for engine and window work. Or, I may just say ‘frig it’ and cover it with a blanket.