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Project Log:  Saturday, May 5, 2012

With plans for varnish later, I lightly sanded all the surfaces in the main cabin to prepare them for the next rounds of work. 

The day's main focus--the only focus, as it turned out--was to build a heat shield above the galley stove.  While clearance above the stove was adequate, the center burner was partially beneath the overhanging deck and cabin trunk, and whether strictly necessary or not I felt some form of heat protection was prudent.  I'd insulate the overhead directly above the stove (i.e. the underside of the sidedeck), as well as a portion of the vertical cabin trunk face above the stove.

To begin, I checked the inside dimensions of the two ports above the stove and determined that the trim rings required an inch or less of clearance.  After checking that the port openings were level, as I expected, I used two lengths of 1" tape to mark out a 2" offset beneath the port openings, which gave me a starting point for the insulation work.

Metal heat shielding alone in this instance probably would have been enough, but for additional heat resistance I selected 1/4" silica insulation, a fabric-like material that exceeded the recommended heat shielding specifications set forth in the Dickenson stove manual.  I chose this material for its various ratings as well as for its convenient fabric-like form, which was easier to ship and easier to work with.  Over the top, for appearance and additional protection, I ordered 24 ga. sheet stainless with a #4 brushed finish, which matched that of the stove itself. 

To avoid compressing the insulation, I needed to build a way to support the metal sheeting over the insulation. To this end, I prepared several pieces of 1/4" x 1/2" cherry stock, which I used to build a little frame inside of which the insulation would be installed; the sheet stainless would be attached to the frame with a molding and screws.  The bottom edge of the green tape I applied to the cabin side demarked the top edge of the insulation frame, and I drew additional layout lines for the sides and the lower section as needed, keeping the frame inside the cabin trunk corner trim I'd installed earlier to allow room for the molding that would secure the stainless panels.

With the layout complete, I installed the hardwood frame with 3-hour epoxy adhesive, using dabs of hot glue to hold the pieces in place while the epoxy set up.


I made a pattern of the inside of the frame, then transferred this to my sheet of insulation and cut it out.  I installed the insulation with a light application of spray adhesive, after first covering all adjacent surfaces with paper to protect them; a few weeks ago, I used the spray adhesive to secure a small piece of hull liner cloth, and, as I'd not used spray adhesive for many years, I'd forgotten (and underestimated) how much overspray there was.  That lesson learned, the extra few minutes to cover all surfaces versus cleaning up the overspray afterwards was well spent, though the spraying took only about 4 seconds.


Next, I milled a molding profile to cover and secure the edges of the sheet stainless and finish off the installation.  The profile overlapped the insulation frame, and extended well out over the field of the area to hold the stainless in place.  I'd left just enough room between the frame and the existing cabin trunk trim to allow the new molding to slip through. 

During the remains of the day, I trimmed the sheet stainless to fit as needed and secured them temporarily with hot glue (a special kind that worked on metal) while I cut and fitted all the pieces of molding around the edges to finish off the  installation. I went with exposed screw heads for the trim so I could replace the stainless or the insulation easily should it ever be necessary.  For the 90° corner between the vertical and horizontal sheets of stainless, I used a special stainless steel corner molding designed for the purpose.


I didn't anticipate, necessarily, that the insulation/heat shielding project would require over 6 hours to complete, but there you are.  In any event, this did not leave me enough time for the varnish work that I'd planned, but before knocking off I started masking off the areas required, beginning with the galley countertop.


Total Time Today:  7.5 hours

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