My main focus now is getting the portholes installed. My painter’s schedule hasn’t synched with mine yet, so I’m temporarily stalled in the V-berth. The new mahogany panel that I’ll bond to the bulkhead there is ready for paint, but until that happens I don’t want to cut the hull side pieces. Any change in that bulkhead panel position will affect the fit to the side panels, and I don’t want gaps. So, I went back into the aft stateroom and started cutting the 1/4″ mahogany plywood that will surround the rest of the porthole openings. I did this before on the two aft-most holes a while back. This time, I started with the aft head.
That tracksaw is a great tool. You get super precise cuts, and the setup for each cut is very fast.
This is a boat, so nothing is ever perfectly square. I learned a while back to cut panels like this slightly oversized, then trim to fit as necessary. Once you make the cut, you can’t add material back if the panel it joins to has a slight curve or angle to it.
The tracksaw is great for making quick cuts at any angle. You can’t easily do this kind of cut with a tablesaw.
I ran around to the outside, and traced the porthole outlines onto the panel.
Once this panel is clearcoated with ICA, I’ll epoxy seal the edges and backside, then insulate the back of the panel like I’ve done on all other panels that face the hull. Since the bathtub/shower will be a source of high humidity here, I’ll bed the edges of the panel with Sikaflex and cover the joints to the walls with mahogany quarter-round molding.