1969 Chris Craft Roamer 46 Refit: Window Patterns

After spraying the shiny Awl Grip Awlcraft 2000 Matterhorn White on the cabintop, helm dashboard, and aft enclosure, there was a brief lull in Boatamalan activity on my Roamer. It turns out that Weaver Boatworks, where they work during the week, is extremely busy–they sold two boats in two weeks, for a total of four boats in production. With a bit of quiet time on the boat, I made window patterns for the Roamer and a bow pulpit for my 1968 Chris Craft Commander 42. I also interviewed a couple of fabricators who will tackle the engine and shaft installation to replace the clown I fired in July 2013.

Google SketchUp’s dimensioning tool makes it easy to plan window sizes.

Electronic plans are nice, but when size is critical I prefer to make full-size templates. So I broke out the scrap 1/4″ sapele plywood and my Eureka Zone track saw and got to cutting.

The aft window pattern is sized to account for arc in the frame.

1/4″ gap all the way around.

In the lower left of the pic above, you can also see the patterns for the bow seat windows. After comparing price and products across many window manufacturers, we settled on Motion Windows out of Vancouver, Washington. The two outer windows will be fixed glass in the 1200 Series frame. The center window will be top-hinged in the 1250 Series frame. The ability to open the window should be terrific for ventilation, and both the 1200 and 1250 Series frames do not have any exterior fasteners that can leak and cause damage to interior cabinetry.

With the window frames cut, I grabbed some of the 8/4 African mahogany scraps that were left over from the toe rail for the Roamer and made a bow pulpit for our Chris Craft Commander 42.

Gorgeous African mahogany scraps, eh?

The pulpit is finished in West System resin and 207 Special Clear hardener in this pic. The epoxy encapsulates the entire piece, and I’ll use more to seal up the bungs when I install it on the boat. I’ll sand it flat, then go over it with a few coats of traditional varnish for additional UV protection.

Almost too pretty for a tough job like a pulpit.

It’s amazing how the sunlight plays with the wood grain.

Next up in our 1969 Chris Craft Roamer 46 Refit: Prepping for non-skid.


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