1969 Chris Craft Roamer 46 Refit: Cutting and Fitting Salon Plywood Panels

With the galley pantry panels installed, I moved on to other panels that face the hull in the salon. The cold winter made it hard to keep up momentum, since epoxy doesn’t kick when it’s too cold. But it was 76°F one day last week, then it snowed over the weekend. Today it will be 78°F. On the upside, the epoxy is finally starting to cure. I just wish it would stay warm enough on the weekend for me to get more stuff done.

Cleats for the next panel that will be installed aft of the pantry

Ready to fit the wall panel

Marine-grade 1/4″ Doug fir plywood fitted in place

The idea here is to have the living space sealed to isolate it from the hull envelope. The hull and decks are insulated, and I insulate the backside of every panel that faces that hull. Since metal boats can be difficult to keep comfortable, temperature-wise, this insulation approach should make my boat a lot warm in winter and cool in summer.

This 1/4″ Douglas fir panel was a bit challenging because the hull starts curving in toward the bow here. The plane of the back and front edges aren’t the same. Once I push the panel into place, the forward edge needs to be slightly curved so it fits closely to the upright galley pantry panel. Tight joints will help ensure there’s no air leakage between the hull envelope and the interior.

Cut the Buffalo Batt insulation to fit

US Composites epoxy resin with 2:1 hardener is my favorite epoxy product

The back-side is thoroughly wetted out and ready for the insulation

Press the insulation in place and go home

Next day, the epoxy still isn’t cured, but it’s tacky enough

Wet out the cleat contact points and seal the edges

Epoxy thickened with wood flour goes on the cleats

Boom! One more insulated panel installed

Next up in our 1969 Chris Craft Roamer 46 Refit: Cutting and Fitting a Toe Rail Vent Duct