Thanks to everybody who hit the tip jar! I really appreciate it!
Before we can spray the ICA top coat in the interior, I have to get the headliner installed. To install the headliner, there has to be a continuous surface all around the perimeter that the Whisper Wall headliner track can attach to. I’ve got most of the the continuous surface installed around the aft stateroom, then I shifted gears and worked on the salon headliner prep. In addition to having continuous surface to attach to, the headliner tracks also need to butt up against finished walls or fascia panels.
Problem: original salon entryway fascia board cracked in half
I considered gluing the board and reusing it, but it wasn’t salvageable
It’ll work great as a pattern, though.
A nice chunk of 4/4 mahogany pulled from the stack
First, I jointed the edge
Next, I jointed the faces
I love this MiniMax FS35 jointer. It’s got a relatively small footprint but can joint or plane boards up to 14″ wide. I wish I had it hooked to my dust collector, but the MiniMax is at home and the dust collectors are at the boat.
Back on the boat, trace the outline of the old board
Lop off the bottom on the EZ-One track saw table
Aft edge has an 88.5° angle
It’s a boat…nothing’s square.
Rounding the lower edges of the board
Nice!
Cutting the aft edge
Router finishes shaping the aft edge
Jigsaw worked well for the leading edge cuts
The new board looks a lot better than the original one
You can see in the above picture where a chunk of mahogany is missing from the original board. That helped nudge me into making a new one rather than gluing the old board back together.
Mark off the next cuts
Confirm the depth of cut on the track saw…need to drop it another 1/32″ or so
Start cutting away
One pass after another
Looks good!
Cleaned up with the router, then cut the next step
That’s looking pretty good!
Perfect fit on the first try!
It’s hard to see in the above picture, what with all of the protective plastic and blankets in place, but the new board is friction-fit to the salon entryway.
Nice little channel
There’s a 2-piece folding hatch for this entryway I’m making that will seal flush with the upper surface of this board.
Need to remove material and make space for the screen track
First, cut the upper and lower edges of the groove for the track
Multiple passes clear the track groove
Done!
You can see the two chunks of missing mahogany on the original board, one at the far left side (the top edge) and the other on the screen track. My new board will look great once it’s sprayed with ICA clear coat.
Next up in our 1969 Chris Craft Roamer 46 Refit: Salon Entryway Sliding Screen Tracks
1969chriscraftroamer46 