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