1969 Chris Craft Roamer 46 Refit: Insulating Mahogany Wall Panels

With the stack of mahogany wall panels finally painted with eight coats of ICA base clear then topped with two coats of semi-matte, the next step involves insulating the back-side of each panel. The hull, decks, and cabin top are already insulated with spray foam, but I’m also using Buffalo Batts to insulate the back of each wall panel that faces the hull to make the boat more comfortable all year-round. Insulating each panel adds a lot of time to the process, but I think it’ll be worth it.

1.5″ thick Buffalo Batt provides R3 insulation value

Cut out areas where the panel contacts frames and mahogany cleats

Wet out the panel with epoxy

The epoxy serves two purposes: it seals the panel, giving it stability over time, and it acts like contact cement to hold the insulation in place and tight to the panel. I kept the epoxy away from the areas where the panel will contact the mahogany cleats that are attached to the aluminum ribs. I’ll wet that out and edge seal the panel, then apply wood flour-thickened epoxy when I bond it in place.

Position the insulation, then weigh it down

Same process for the aft stateroom transom cabinet panels

Aft stateroom porthole surround panels get the same treatment

Done insulating…time to let the sticky epoxy cure

Next day, epoxy is cured

Headboard shelf panel should stay warm to the touch, even in winter

Insulated on one side, pretty mahogany on the other

Ready to install

Buffalo Batt: R3 insulation value in 1.5″ of woven fabric that doesn’t absorb water or itch

That’s it for the insulating. Now for the fun part!

Next up in our 1969 Chris Craft Roamer 46 Refit: Installing the Port V-berth Mahogany Wall Panel


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