Winter is over and work has begun again, for the third season. The new exhaust extension tube was bonded into place. It allows the engine exhaust to pass through the original transom through the area under the swim step and exit through the bottom of the sugar scoop above the water line. The exhaust hose is some 20 feet long and forms a loop high above the deck in the engine room before exiting to the rear of the boat. Bonding it in place had to be done prior to making the swim step and scoop storage cabinets. The cabinets will be water tight and do not empty to the bilge. The cabinet bottom is flush with the swim step between the cabinets. The area under the swim step is dead space, but a deck plate will be installed for periodic inspection. The cardboard mock up will be used to trace patterns on pre-made sheet glass then bonded together to make the cabinet. The corners will be somewhat rounded when complete. A center “U” shaped step, centered above the boat name will complete the step from the sugar scoop to the aft deck.
The card board mock up is taken apart and laid onto a preformed white gelcoat fibreglass panel. The part outlines are traced onto the masking tape prior to cutting. The masking tape reduces the chipping at the edges when cutting. Most of the corners will be trimmed and rounded over in the final steps, so chips are not detrimental here.
Next the parts are cut and will be sanded to final shape as necessary.
Here we can see some of the parts that make the sugar scoop cabinets. The remaining parts are made by taping and marking the outlines upon waxed window glass. Oscars OP-600 is the best wax I have found for this purpose. Three to five coats of wax are applied.
Then the outlines marked with masking tape. Note the black 2″ tape in the middle of the two larger panels and the orange ladder recess mold. These two larger panel will be joined to make the swim step platform. I used 3 layers of black Duck tape over 3M blue tape. Duck tape is very difficult to remove from the glass is applied directly. The thickness will allow me to tab the cabinet sides to the platform and later fillet into the gelcoat. White gelcoat will only be applied to the square area of these panels and the two smaller panels. The rest of the panel will be inside the lockers which can be painted white after final assembly.