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Project Log:  Saturday, October 6, 2012

The next step in constructing the settee back cushion/locker doors was to hang the doors with their hinges, and secure the upholstery panel to the structural panel.  With each door in place, and held in the proper position by the temporary cleats I'd glued in the openings earlier, I secured flush brash hinges in place.  The hinges didn't come with their own screws, and since this was a temporary installation I used some stainless steel screws I had on hand to secure them.


Once I had the hinges in place, I removed the lower part of the hinge from the cabinet, then laid out for a series of four screws to secure the front panel (which would hold the cushioning and upholstery) to the back part of the panel.    Here, I chose threaded inserts and machine screws, along with a 1/8" spacer to provide room for the eventual upholstery on the back side of the panel.  For each panel, I marked for and drilled pilotholes for the screws, then slightly larger holes to accept the threaded inserts, which installed with their own external threads.


When assembled, the two sections acted as one, and provided the requisite space between. 

I resecured all three doors to check the fit and function before removing them again to send to the upholsterer in the near future.


In the forward cabin, in order to have the berth area templated accurately for the mattress I needed to simulate the thickness of the wooden ceiling (hull liner).  Since I wasn't sure when I'd actually purchase the materials for and install the ceiling, I made up some simple sections of scrap plywood, one for each side, that I could secure to the support strips as required for templating.  These extended high enough (over 6")  so that both top and bottom profiles of the mattress thickness could be accurately measured.

For now, I removed the plywood so I could paint the hull and surrounding area before continuing other work in the forward cabin.


Next, I decided to continue work on some trim pieces, this time in the pilothouse.  All the various corners and seams between plywood veneer panels required trim of one form or another, including four sets of wire chases at the forward end.  I began with the two wire runs leading up the sides of the center section.  From solid cherry I conceived then milled sections of trim to fit, incorporating space for the wires and wire supports and thick-enough edges to allow for small screws to secure the trim. 

Once I'd milled the requisite trim, I used short sections to determine the proper angles to cut the top and bottom, then cut the two sections to fit.  I'd not install these permanently till after I'd varnished them.




The trim for the two side corners at the forward end also needed to cover wire runs, but these areas were complicated by close clearances with the aluminum frames from the side windows.  The windows were slightly asymmetrical from side to side, so on the starboard side there was more room next to the trim than the port side.

After some thought, I came up with a trim profile that I thought would work, and milled a section.  Cutting off an end piece (which featured some edge damage from the lumberyard), I tested the concept in place, but the final execution would have to wait till next time.


Total Time Today:  6.5 hours

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