Installing the Bulwarks

Bulwark components are long-scarfed from marine-quality pressure-treated 2x4's

Using a 1/2" Drill Motor with a 3/8" square-drive and socket to install 1/4" x 5" hot-dipped-galvanized lag bolts 18" on center. Care must be taken not to break the bolts: tighten snug only; tighten further by hand using a rachet wrench. All bulwark components are "dry-fit" before glue. Bolts are left 1/2" up; bulwark layer is lifted with a prybar (see photo), glue is inserted with a 3" putty knife; lags are tightened.

Bulwark first layer on

Clamps are used to roll the bulwark in amidships to make it nearly verical. The bulwarks roll out in the ends to match topsides flare

Dry fitting the second Bulwark layer while torturing it into place. I broke this one at a scarf joint pulling the aft end in. Clamps align and torture

Using a flat bar to open the glue joint between layers.

3/4" Bungs are installed using lots of epoxy to cover and seal the bolt heads. Bungs are cut using a 7/8" hole saw in the drill press.

Coachroof Construction

Coachroof Beams being varnished prior to installation; note routed mortises for Skylight Carlins

Coachroof Beam-ends showing rabbets for 3mm headliners & 3/4" polyurethane foam core

Aft Hatch Coaming with handle mortised into Coachroof Beam

Aft Coachroof in frame

Fwd. Cabin Coachroof in frame

Fabric/epoxy covering Houses (ends covered first)

Skylight Frame

All exterior fabric/epoxy work completed; Cockpit Pedestal in place (for compass & engine controls)

Sheathing the Decks

Fabric/epoxy covering Decks

Decks covered; portlights cut out