After the demolition was complete I let the area dry out for about a month.  I ran a boat Caframo Air Dryer right in the hole.  The strength of the stick built cabin sole is amazing.  I could walk around the unsupported area with little flexing.

I could feel a challenge coming up.  The sole curves up from the center and the existing floor thickness is variable from top to bottom due to the filler.  There is no way to simply lay in a single piece and have it easily align on all sides.  I decided to build it back up in many pieces. There is also the issue of how to match the coloring and grain.  I decided to take it one step at a time and see how things materialized.

I had to come up with a way of supporting the new underlayment and bonding with the existing floor.  I decided to make some brackets out of 1/4″ G10 epoxy board and bond them to the existing sole.  I used 1/2″ Meranti ply to make a new shower support.  I decided to double it to improve rigidity.  I templated the new support before cutting and sealed it with a few coats of straight west system.

1/4″ G10 epoxy board brackets to support sub-floor

Fitting new shower support

After the new support was fitted and brackets installed, I templated using a piece of 3/16″ luan ply and transferred to the Meranti 1/2″.  To deal with clamping and curvature I drilled and tapped 10-24 holes in the G10 for mechanical fastening.  For fastening into the mast support beam I reused the 1.5″ slotted wood screws that came out during demolition.  Note that I filled all the old screw holes with west in an epoxy syringe.  I also did some drill samples in the beam and step to make sure there was no water damage inside.  Everything looked pretty dry.

I used epoxy on the brackets, shower support and subfloor edges (not where it is attached to the beam).  This will allow the patch to be removed if I ever opt for a complete sole replacement in the future.

Subfloor patch installed. Edges were sealed with two coats of epoxy. Things looking better already.

After I fastened the ply I cut a slot in the center and inserted a small piece of ply as a center support.  The piece was epoxied to the hull underneath.  I also epoxied in the new shower support and screwed the subfloor to it.

Poor shot of new shower support with thickened epoxy seal. This will be covered with cloth later.

I have always enjoyed night passages especially the morning watch.  Seeing the sun come up on the water reminds me of the boundless aspects of sailing a small boat on a big ocean.

Nothing like enjoying a nice cup of coffee while shaking off the night chill as the sun comes up.

Perfect conditions for reflections on life.

Unknown tall ship at dawn in the Gulf of Maine 2009

Headed East at dawn

Motoring at dawn in the calm waters of Long Island Sound during an overnight delivery 5/2013

Morning coffee off Nova Scotia – Marblehead to Halfiax

Most non-obsessed owners put their boats away over the winter.  From the fall to a reasonable point in the spring (mid-April?) the boats are covered, stuffed in a boat yard somewhere and  remain untouched.  The better heeled crowd may have their boat stored inside at reputable yard where pros may be doing larger projects.

For me working on the boat is therapy year round  so no reason to stop when others head for  Florida or the ski slopes.  I am lucky because I have the boat stored on my property (actually my driveway), I live in a town where this is allowed and acceptable (I am sure some of my neighbors are like WTF) and my wife lets me keep it there.  Also, I can do it because I drive a car with a low roofline and have a boat with nice bow overhang.  So the car goes under the boat about six feet, fitting like two puzzle pieces.

The boat stays plugged in with the battery charger on float and a few small space heaters are at the ready for when a project starts calling.  Yes, you do get strange looks from the neighbors when they see you on the ladder climbing in during a snow storm.

Using the heaters I can get the cabin warmed up for general work.  I have also done some epoxy/glass work by keeping one of the heaters focused on the work area until the epoxy is completely set (10-12 hours).

Today was a good example.  Relaxing Saturday – I wanted to get a few hours in on the autopilot project.  Patagonia thermals under the work pants, thermal socks and heavy hoodie pulled over a winter hat.  Put a heater down in the aft lazarette and I am ready to go.