I decided a while back to shift from closing up bilge vent ducts and start using up the remaining 1/8″ mahogany plywood. There was one 4′ x 8′ sheet and a bunch of big cut-offs, and I was getting sick of moving them around to get to other stuff. Fortunately, there was just enough of that plywood to veneer the OEM cabinets in the galley and salon. I finished the galley cabinet interior first, then wrapped up the aft salon cabinet (which I think turned out really nicely). Next I wrapped up the forward salon cabinet.
The salon forward cabinet before the veneers
The same cabinet interior with a mahogany floor and back panel
Chris craft didn’t make a closed cabinet box here, so you can see the hull from inside the cabinet. Since I’m trying to create an insulated envelope in the living spaces, I need to make an interior wall panel for that cabinet and then insulate the backside using R3 Buffalo Batt before installing it.
New outer cabinet wall
Framing out the new wall attachment points
Because there is a vent fan in this space, the wall I’m making will need to be removable just in case the fan needs service sometime in the future.
Test fit looks OK
Upper panel fits tightly to the wiring without pinching
As you can see, I didn’t bother with veneering the parts of the cabinet that aren’t visible unless your head is inside of it. I don’t feel it’s necessary to buy another sheet of mahogany just to make practically invisible parts of this cabinet pretty.
Backside of the panels got insulated
I also saturated the panel edges with epoxy to fully seal them. There’s little chance of water ever getting in to this panel, but I want to be consistent throughout the refit so I don’t get surprised with a panel failure sometime down the road.
Cleats and the panels are ready to install
As with everywhere else, I’m using epoxy to glue and then screw the cleats in place. Once it cures, they’re much more rigidly attached than when you only use screws.
Test fit the mahogany veneer panels on the newly installed wall
After wetting out the plywood with epoxy and then applying a bit of wood flour-thickened epoxy, I used a bunch of sticks and plywood scraps to press the panels in place.
Pressing the inner and outer mahogany veneers in place while the epoxy cures
Next day, the sticks come out
Last up: the shelf
Nice!
The hole you see at the top of the mahogany panel in the cabinet is the opening for the 1968 Edison brand toaster that was on the boat when we started this whole thing. I sent the toaster off for rechroming a few years back, and it’s a real thing of beauty. I look forward to the day when I install it.
Anyway, that’s a wrap for the OEM cabinet interiors. I only have to make fiddles to cover the leading edges of the plywood shelves and install the doors, which are already sprayed in ICA base and top coat clear urethane. Next, I’m going to start on the starboard side of the salon.
Next up in our 1969 Chris Craft Roamer 46 Refit: Removing the Original Electric Panel
1969chriscraftroamer46 
I have really enjoyed sharing the journey. I am just finishing off a complete refit of an absolutely tiny boat by comparison (5 years) and will be starting on my Healey this year (have owned it since 89) I don’t think I have it in me any more to do a project like yours. Attention to detail has been really good to see!
Post a Pic. of the Toaster– Would love to see it..