F/V ESCAPE HATCH
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Phase 4
Cabin and deck

This page and all the links within have to do with the cabin and the deck. 

includes:
  • cabin and deck layout (hatches,equipment, etc)
  • cabin and deck supports
  • install windows
  • hatch supports
  • raised bulwarks enclosing walkaround area
  • install masts
    • flag pole with all around/stern light
    • radar pole
  • paint deck and cabin
  • no slip material on deck
  • Boom
  • Bait tank
Cabin and Deck 
  • use 1.25"x 2.5" stock for framing
    • use a modified butt joint as in Ray Macke's build
      • Butt joint is angled
  • Use 1/2" plywood for cabin bulkhead
  • Use 3/4" plywood for decks

Paint and primer

  • Blue Water Marine Paint System
    • Wash
      • 973 Dewaxer - $24.45/gal
    • Primer - $342.25
      • Bottom Protect Primer 8000A - $68.45/gal
        • ~400sqft/gal
        • Deck and cabin - 371.75 sqft/coat
          • deck - 110.75sqft
            • cockpit - 48.75sqft
              • lower
                • 7.5' x 4' = 30sqft
              • upper
                • 7.5' x 2.5' = 18.75sqft
            • walk-around - 62sqft
              • sides - 48sqft
                • 16' x 1.5' = 24sqft
              • bow - 14sqft
                • 7' x 2' = 14sqft
          • cabin exterior - 261sqft
            • Roof - 104 sqft
              • ~16' x 6.5' = 104sqft
            • Bulkheads - 139sqft
              • Sides - 87sqft
                • Pilothouse/salon
                  • 13' x 6' = 78sqft
                • Berth
                  • 3' x 3' = 9sqft
              • Aft - 42qft
                • 6' x 7' = 42sqft
              • Fore - 10sqft
                • 5' x 2' = 10sqft
            • Boot Roof
              • 3' x 6' = 18sqft
        • 3-5 coats
    • Paint - $628.16
      • Revolution - $157.04/gal
        • topside paint good for up to 7 days in the water
        • ~400sqft/gal
        • Deck and cabin - 371.75 sqft/coat 
          • deck - 110.75sqft
            • cockpit - 48.75sqft
              • lower
                • 7.5' x 4' = 30sqft
              • upper
                • 7.5' x 2.5' = 18.75sqft
            • walk-around - 62sqft
              • sides - 48sqft
                • 16' x 1.5' = 24sqft
              • bow - 14sqft
                • 7' x 2' = 14sqft
          • cabin exterior - 261sqft
            • Roof - 104 sqft
              • ~16' x 6.5' = 104sqft
            • Bulkheads - 139sqft
              • Sides - 87sqft
                • Pilothouse/salon
                  • 13' x 6' = 78sqft
                • Berth
                  • 3' x 3' = 9sqft
              • Aft - 42qft
                • 6' x 7' = 42sqft
              • Fore - 10sqft
                • 5' x 2' = 10sqft
            • Boot Roof
              • 3' x 6' = 18sqft
        • 2-4 coats
      • thinner needed
        • ​​​974 thinner - $24.45/gal
  • Interlux Brightside paint system
    • Wash
      • Solvent wash 202 - $18.99/qt
    • Primer $639.80
      • Pre-Kote $31.99/qt (4qts=1gal)
        • ~100sqft/qt
        • Deck and cabin - 371.75 sqft/coat
          • deck - 110.75sqft
            • cockpit - 48.75sqft
              • lower
                • 7.5' x 4' = 30sqft
              • upper
                • 7.5' x 2.5' = 18.75sqft
            • walk-around - 62sqft
              • sides - 48sqft
                • 16' x 1.5' = 24sqft
              • bow - 14sqft
                • 7' x 2' = 14sqft
          • cabin exterior - 261sqft
            • Roof - 104 sqft
              • ~16' x 6.5' = 104sqft
            • Bulkheads - 139sqft
              • Sides - 87sqft
                • Pilothouse/salon
                  • 13' x 6' = 78sqft
                • Berth
                  • 3' x 3' = 9sqft
              • Aft - 42qft
                • 6' x 7' = 42sqft
              • Fore - 10sqft
                • 5' x 2' = 10sqft
            • Boot Roof
              • 3' x 6' = 18sqft
    • Paint $575.84
      • Brightside - $35.99/qt
        • ~100sqft/qt or ~400sqft/gal
        • Deck and cabin - 371.75 sqft/coat
          • deck - 110.75sqft
            • cockpit - 48.75sqft
              • lower
                • 7.5' x 4' = 30sqft
              • upper
                • 7.5' x 2.5' = 18.75sqft
            • walk-around - 62sqft
              • sides - 48sqft
                • 16' x 1.5' = 24sqft
              • bow - 14sqft
                • 7' x 2' = 14sqft
          • cabin exterior - 261sqft
            • Roof - 104 sqft
              • ~16' x 6.5' = 104sqft
            • Bulkheads - 139sqft
              • Sides - 87sqft
                • Pilothouse/salon
                  • 13' x 6' = 78sqft
                • Berth
                  • 3' x 3' = 9sqft
              • Aft - 42qft
                • 6' x 7' = 42sqft
              • Fore - 10sqft
                • 5' x 2' = 10sqft
            • Boot Roof
              • 3' x 6' = 18sqft
    • Thinner
      • Interlux 333 - $20.99/qt
Windows:
  • Laminated Safety glass - $2,686.87
    • less chance of shattering and having shards(sharp or not) all over the cabin and bilge.
      • Front window - 2 panes - $518.12
        • ~32.25" W x 34.5" T x 1/4" thick
          • $259.11/pane
      • pilothouse side window - $575.28
        • Large front -1 each side, 2 total
          • ~33.5" W x 36.5" T x 1/4 thick 
            • $287.64/pane
        • Small front - 1 each side, 2 total
          • right triangle
            • A = ~29.25"
            • B= ~ 10.25"
            • C= ~ 31"
        • Rear - 1 each side, 2 total - $226.26
          • 11.75" W x 34" T x 1/4" thick
            • $113.13
      • salon windows
        • side - 2 per side, 4 total - $1,033.64
          • 35.25" W x 30.5" T x 1/4" thick
            • $258.41
        • rear - 3 - $333.57
          • ~14" W x 29" T x 1/4" thick
            • $111.19
Raised Bulwarks and rails around gunwale
  • 2"x 2" posts set at 16"- 20" apart
  • Use 1/2" plywood for outside skin
  • Either make Scupper holes where Bulwark and hull meet or just don't extend bulwark all the way to the hull.
  • Doors built into both sides at Pilothouse and Cockpit steps
Masts
  • Radar
    • ​about 4' tall
      • can build or buy
        • build
          • Use a birds nest method to create a hollow mast
            • create a wedge in one side of board that the mating board fits into perfectly creating more glue area and a mechanical joint
          • Epoxy coat inside and outside and PU paint
        • buy
  • Flag pole with all around light
    • About 8' tall
      • Can build or buy
        • build
          • Use a birds nest method to create a hollow mast
            • create a wedge in one side of board that the mating board fits into perfectly creating more glue area and a mechanical joint
          • Epoxy coat inside and outside and PU paint
        • buy
Deck Hatches:
Most are built out of the deck material it's cut out of. No real additional expense.
  • Cockpit
    • Ice hold # 1
      • 18" x 24"
    • Ice Hold #2
      • 18" x 24"
    • Rudder access hatch
      • 12"x 24"
    • Storage hatch
  • Gunwale
    • storage hatch
  • Salon
    • fuel access hatches
    • Motor box
      • insulated for heat and sound
        • 28" x 39"
  • Pilothouse
    • electrical access
    • battery access
      • 12" x 27"
    • bilge access
  • Berth
    • bilge access
      • 18" x 12"
    • water tank and pump access
Cabin hatches
  • Rear Salon
    • horizontal sliding hatch with window
      • 21" x 73 3/4"
      • window is 16" x 27 3/4"
        • $137.96
  • Helm Pilothouse
    • Horizontal sliding hatch with window
      • 21" x 53 1/4"
      • window is 16" x 27 3/4"
        • $137.96
  • Admiral Pilothouse
    • Horizontal sliding hatch with window
      • 21" x 53 1/4"
      • window is 16" x 27 3/4"
        • $137.96
  • Berth to bow
    • 2 hinge vertical hatch with window
      • top
        • 25" x 20 1/4"
      • front
        • 25" x 23 1/2"
        • window is 22" x 20 1/2"
          • $137.08
  • Head
    • regular hung door
    • closes off both head and berth
      • 24 3/4" x 62"
Bait Tank
  • Fiber-glassed plywood with PVC hoses and valves
    • 1/2" plywood
      • with rounded corners using built up 3mm-1/8" ply.
    • 1/4"-1/2" plexiglass
  • a handwell
  • pressurized system to prevent sloshing
  • Lighted
Boom
  • nested square steel
    • Outer square - 1
      • as long as cabin is wide
    • Middle square - 2
      • about half as long as outer square.
      • nests in outer square
    • Inner Square - 2 
      • Same length as middle square
      • nests in middle square
Non-slip deck
  • Sea-Dek- can do custom. Stock items below.
    • long sheet - $77.95/each
      • 18"x74"
      • 5mm thick
      • to do all interior decks I estimate 4 sheets
      • use white or mocha
    • Large Sheet - $149.95
      • 39"x77"
      • 5mm
      • to do all exterior decks I estimate 8 sheets
      • use caribbean blue or white
    • Coaming bolster pad - $105.95
      • 4.5"x37"
      • 20mm thick
      • to do all raised bulwark coaming I estimate 18 sheets
      • use white color
    • Small Helm Station Pad - $102.95
      • 14"x36"
      • 13mm thick
      • To do both helm and admiral station need 3 sheets
      • use white over storm-gray
    • Custom colors
      • Outside
        • 5mm base with 3mm veneer
        • Bimini Blue Base
        • White or Caribbean blue veneer
      • Inside
        • Teak colors
      • Helm station
        • teak
      • Coaming bolster
        • Bimini Blue Base
        • white or caribbean blue veneer
  • epoxy/paint non-skid additive
 Materials estimate
  • Cabin Lumber
    • 2.5"X1.25" - 336' ~87.5bdft @ $6/bdft = $525
      • 7ft salon/pilothouse uprights - 14 = 98'
      • 13.5' salon/pilothouse longitudinal rail - 4 = 75'
      • 5.5' salon/pilothouse athwartship rail - 10 = 55'
      • 5' berth uprights - 10 = 50'
      • 10' Berth  longitudinal rail - 4 = 40'
      • 6' berth athwartship rail - 3 = 18'
  • Cabin Plywood - 15 sheets 1/2" Marine DF AB plywood @ $63.90/sheet = $958.5
    • aft bulkhead
      • 6'x7'= 42sqft
        • 2 sheets plywood
    • Side Bulkheads - 
      • 13'x5'= 65sqft/side
        • 3 sheets plywood/side
        • 2 sides, need 6 sheets plywood
    • Salon roof
      • 7.5'x6.5'= 48.75sqft
        • 2 sheets of plywood
    • Pilothouse roof
      • 8'x6.5'= 52sqft
        • 2 sheets of plywood 
    • Berth outside bulkheads
      • sides
        • 3'x3'= 9sqft
          • 1 sheet of plywood
      • fore
        • 5'x2.5'= 12.5sqft
          • 1 sheet of plywood
      • Roof
        • 5'x3.5'= 17.5sqft
          • 1 sheet of plywood
  • Deck Lumber 2.5"x1.25" - 190.5' = 49.61 bdft @ $6/bdft = $297.66
    • rear cockpit - 64'
      • longitudinals 4.5' - 8 = 36'
      • athwartships 7' - 4 = 28'
    • Raised cockpit - 36'
      • longitudinals 2.5 - 6 = 15'
      • Athwartships 7' - 3 = 21'
    • Gunwale W/A Cockpit to boot - 56'
      • longitudinals 13' - 2 = 26'
      • athwartships 1.5' - 20 = 30'
    • Gunwale W/A boot bow - 34.5'
      • longitudinals 3' - 2 = 6'
      • Athwarthships 1.5' - 6 = 9'
      • bow longitudinals 3' - 5 = 15'
      • bow athwartships 4.5' - 1 = 4.5'
  • Deck Plywood - 6 sheets 3/4 Marine DF AB @ $83.90/sheet - $503.40
    • rear cockpit - need 2 sheets
      • 5' x 7.5' 
        • need 2 sheets
    • Raised cockpit - need 1 sheet
      • 8'x2.5'
        • need 1 sheet
    • Gunwale W/A cockpit to boot - need 2 sheets
      • 13'x1.5'/side
        • need 1 sheet/side
        • have 2 sides need 2 sheets
    • Gunwale W/A Boot to bow - 1 sheet
      • 3'x1.5'/side
        • need 1/2 sheet per side
        • have 2 side need 1 sheet
    • Epoxy - $1,157.80
      • Encapsulating
        • Poxy-Shield - 1.2gal kit $124.75 - 6 gal kit $578.90
          • ​Estimate need 1- 6 gal kit - $578.90
      • Fiberglassing
        • ​Poxy-Shield - 1.2gal kit $124.75 - 6 gal kit $578.90
          • ​estimate need 1 - 6 gal kit - $578.90
    • Fiberglass
      • should have plenty left over from roll in phase 2
    • Fasteners - $145.98
      • Kreg Stainless Steel Pocket Screws
        • ss 1.5" washer head - $72.99/500
          • estimate need 2 boxes
Phase 3: Guts
Phase 5: Completion

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  • Home
    • Escape Hatch blog
    • Escape Hatch - The Band
  • My story
    • My Everything's
    • Contact me >
      • Ad policy
  • Project
    • Project - Phase One - Prep >
      • Fundraising
      • Documentary Plans
      • Boat Plans >
        • Boat Price estimate
        • TG/CC Concept Plan
    • Project - Phase Two - Hull
    • Project - Phase Three - Guts >
      • Electrical System Plan
    • Project - Phase Four - Cabin and Deck
    • Project - Phase Five - Completion >
      • Trailer
    • Project - Phase Six - Operation >
      • Maintenance
    • Project Status
  • Goals
    • Other goals >
      • House Projects
      • Gardening
      • Blacksmithing
  • Knowledge links
    • Blacksmithing Links and knowledge base
    • Boat Building Links
    • Veteran information
    • Fishing Information >
      • Species Specific Info
      • Trolling
      • Boat Handling
      • USCG Aux Safety Course