Thursday, October 2, 2014

Seat backs installed

Time now to install the seat backs.  I didn't have any clamps that would work for this job (though I am thinking I will make some of the deep-reach cam clamps in the latest WoodenBoat magazine for future jobs like this), so I resorted to using screws.  This worked pretty well,

though it left a bunch of screw holes to fill.

With the seat backs in place I cut and installed the little triangle transition pieces.  The ones included with the kit didn't fit quite right, so I cut my own from scrap.  Masking tape holds the part while the epoxy cures. 

I then rounded the outer edge and filleted the inner curve and appliet a bit of fiberglass cloth.  I like the way the cloth shifts to cover complex shapes like this without the need of cutting any darts or anything.

I saturated that with epoxy.

and put a piece on the inside, too. 

And also took this opportunity to put fiberglass tape along the deck/cabin side joint. 

Here's my first pass with the fairing mixture.  It sagged a little on the vertical surface.

And here's after a bit of sanding.  This still has a ways to go before I'm done.

I then turned my attention to the reinforcing rail on the seat back.  I made this from two thin strips, so I was able to clamp them in place without steam bending.  

I first laminated them  in place on the seat back, but not glued to the seat back.  After the epoxy cured I then took the lamination off and cleaned up the bottom edge, tapered it toward the rear end, and rounded over the bottom corner with the router.  Then I took the result and glued it in place on the seat back.

I cut and fit the return on the front edge,

And trimmed the back to length. 

A little bit of sanding finished it off.

I plan to install a cap on top of this about 1/2" thick.  That will cover the exposed edge of the plywood and allow me to put a nice generous round over on to make it more comfortable to have an arm resting against.  I may also add a wider section if I find that I like to sit up on the rail.  I didn't know where the best place for that would be at this point, so that's a future item.

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