I’m getting close to wrapping up the ‘behind the scenes’ cabinetry in the salon. By which, I mean the installation of the plywood panels that are insulated on the back-side with Buffalo Batt non-woven fabric. The port side is already done, as is most of the starboard side. There are just two more panels I need to install in this area, and I wrapped up the framing for one of those, then cut the panel and insulated it in my last article. Once that’s done, I can move on to completing the aft stateroom bilge vents and surrounding cabinetry, at which point the topsides will be almost weatherproof.
The next panel needs to fit against the new mahogany cleats AND that engine room blower outlet
But first, the blower outlet needs some work
The barrier coat Chris Craft used here didn’t hold up long, probably because it appears none of the aluminum was sanded or otherwise prepped for paint.
The white powder is aluminum oxide, and there’s lots of it
The top and bottom screws securing the base plate to the welded-in outlet came out just fine. The left and right screws…not so much.
My Harbor Freight Dremel-style tool helped with screw removal and surface prep
More aluminum oxide under the screw head
Second screw comes out the same way
Once the screws were out, I continued cleaning up the mating surface and interior of the vent outlet until all of the aluminum oxide was gone and exposed aluminum was sanded bright.
Customized acid shop brush will help apply the epoxy inside the outlet
The hooked brush will allow me to paint the interior of the exhaust duct.
White-tinted epoxy coats the duct outlet inside and out
Next, I cut the hole in the panel for the ER blower
I messed up on the order of operations here. I should have cut the hole and done the final fitting of the panel before I insulated the backside. That Buffalo Batt insulation makes panel cutting much more difficult than it needs to be. Major rookie move…
Ready to test fit
Looks good
Next, I removed the panel, epoxied the edges, wetted out the mahogany backing cleats, and applied Sikkaflex 291 LOT sealant to the vent duct mating surface. In the interim, I’d also finished installing the last starboard salon duct, which you can see to the right of the pic below.
Glued, screwed, and clamped in place
I only have one more insulated ceiling panel to cut and fit inside this cabinet, and this part is a wrap. Making the pretty mahogany cabinet interior can come later and will be relatively easy, since I won’t have to spend so much time cramped up inside the cabinet.
Next up in our 1969 Chris Craft Roamer 46 Refit: Wrapping Up the ‘Behind the Scenes’ Starboard Salon Cabinetry
1969chriscraftroamer46 
All the things you’ve mentioned throughout the Blog– I’m surprised Chris Craft didn’t do a better job at the factory.. Maybe back then they didn’t know any better??
PS: One day I would love to see Pics. of your other C.C. IE: Engine Room..
I’m guessing Chris Craft was mostly interested in cranking out boats as fast as the craftsmen could go. They never planned or engineered for these boats to still be in service half a century later.
I’ll be getting into the ER again soon. I need to weld up the raw water inlet pipes for the engines, and I want to do that before fall sets in.
Stay tuned!
Cheers,
Q