There are many interior angles on the exterior of this Roamer, and Chris Craft smoothed many–but not all–of them with fillets. Since hard, non-filleted angles are weaker, subject to collecting dirt, harder to wash and tend not to shed rain as well, we’re putting fillets pretty much everywhere there’s a visible, hard interior angle.
We used the same homemade fairing compound we’ve been using for the whole project: US Composites 635 epoxy with 3M microballoons and cabocil (in a 3:2 ratio), mixed to a peanut butter consistency.
The fillet on the cabin top-to-deck seam covers a heavy layer of 1708 bi-axial fiberglass that we applied over that seam. This approach should be far superior to the painted 1″ quarter-round mahogany that Chris Craft originally used to seal that joint that I talked about in an article on fairing the cabin top.
No more leaks, and looks a whole lot cleaner than the original quarter-round mahogany.
At the edges of the new bow seat, we’re using a smaller fillet than what we used down on the deck. But it’s larger than the original fillet that came out of the Chris Craft FRP mold. Hopefully, when combined with the geometry changes we made when we built the seat, it will shed water (and dirt) better than the original, tight radius corner.
Out of the original Chris Craft mold, there were no fillets to speak of here. Everything was pretty much hard corners, which collected dirt and propagated cracks.
The fairing compound on the deck here covers the welded seam where once there used to be the transition from aluminum decks to teak.