Continued Focus on the Brightwork

November 25, 2015

Westsail 42....coming soon.

I'll just come right out and say it folks...I have no pics for you today - full apology.  My focus, and I guess I was extremely focused today, was to continue the dry-fitting of the brightwork.  I managed to removed the recently installed toe rails, which included having to hacksaw through about 6 of the #10 fasteners.  In the process of installing the toe rails last week I managed to break-off the heads of these six fasteners.  In the spirit of full disclosure, I must admit to you that I used the wrong drill to secure the toe rail fasteners during the dry-fit stage...an impact wrench.  I used it to speed up the process of drilling pilot holes and securing the fasteners while not having to change the drill bit each time.  Because I could not find my alternate drill, I conceded to the use of the impact wrench.  My plan to deal with the unusable hole in the toe rail is to simply fill it with a bung, and then drill a new fastener hole an inch to an inch and a half from this "mock" fastener hole.

I used a grinder to take off the portion of the fasteners I had removed with the hacksaw. I ground the stub ends down to the deck level being careful not to grind into the fiberglass.  I also ground down the stub end sticking out of the underside of the toe rail.  Satisfied with the toe rails and having a plan for their eventual finish installation, I turned to the coaming boards.

I first took the port coaming "blank" and fitted it to its eventual home by making several angle just with a small Japanese saw.  With the port coaming board roughed-in, I then placed the starboard coaming board in its position and then used a jack and a small length of  1" X 2" to press the boards into the molded fiberglass coaming shape.  With the boards pressed into the position they will hold when finally installed, I marked along the outside of the coaming board at the point where the board rose above the molded fiberglass backrest for the cockpit seat.  I later used this line to position the fasteners for installation.  The boards were both about 71" in length.  I spaced out the position for eight 1/4" philips head machine screws. I pre-drilled on the marks, and then followed up with a 1/4" pre-drilling.  

After both boards where pre-drilled for their fasteners, I once again placed the boards in their final resting position secured with the jack and brace.  With the boards in position, I used #7 drill bit to marked the point on the molded fiberglass backrest for pilot holes.  I then removed the boards, and with the #7 bit, I drilled holes for the fasteners.  Before I dry-fitted the coaming boards, I tapped for the 1/4" machine screws.  After the fastener holes were tapped, I again mounted the coaming boards with the jack and brace and secured the port coaming board.  The 1/4" machine screws are mounted with finish washers and backed with 1/4" nuts and washers.

I will complete the starboard coaming board tomorrow and then turn my attention to the preparing for installation of deck hardware.

Total Time: 5 Hrs.