With the Helm Door Frames in Heavy Mahogany, Aft Deck Transom Mahogany Panels, and Transom Door Step-through Mahogany Filler Pieces all cut and dry-fitted, the next step was to varnish them with catalyzed ICA base coat polyurethane.
I used my Mirka sander and Mirka Abranet 220 grit paper to prep all of the wood
Center transom panel is ready for ICA
After sanding everything, I blew each piece off with compressed air and positioned them for painting
More wood to be varnished in the salon
First coat of ICA on the big helm door frames and starboard transom panel
Love that ribbon stripe mahogany porn
I used a 1/4″ nap 6″ roller and a 3″ foam brush to roll and tip the varnish
ICA is meant to be sprayed, but it rolls and tips pretty nicely
ICA is catalyzed, and was dry to the touch after 15 minutes, which is about the amount of time it took me to roll and tip all of the pieces. After applying three hot coats, one after the other, I left the stinky tent and went home.
Next day, I sanded the ICA with 220 grit Abranet and laid on three more coats
I first sanded all the flat surfaces, then used a hook and loop foam pad + Abranet to sand the radiused corners
Everything is sanded and wiped clean
I wanted to give the dust time to settle before applying the next coats of ICA. So I installed the aft deck mahogany pieces I varnished previously.
Everything is attached using epoxy thickened with wood flour
I had to go a little crazy with the push sticks and levers to hold everything in place so the joints will be nice and tight. They were a great friction fit when dry, but the epoxy acts as a lubricant and the parts weren’t staying in place without some help from the various sticks.
That’s really coming together nicely
Back to the ICA.
After a final wipe-down, I applied three more hot coats of ICA base coat
Done!
I came back the following weekend and removed the push sticks and clamps.
Looking good!
Those are pretty nice looking corner joints
Next up in our 1969 Chris Craft Roamer 46 Refit: Installing Pretty Aft Deck Mahogany
1969chriscraftroamer46 
To help keep wood joints tight after slippery glue has been applied, early woodworkers sprinkled a few grains of fine sand into the glue and between the joints. The sand inhibits the wood from sliding as pressure is applied. It only takes a few grains of sand to have a big effect. It doesn’t seems to affect the strength of the glue. You might give it a try.
Paul, that’s an excellent piece of advice about the sand! As a weekend warrior, there’s a ton of old wisdom I don’t have. It’s always great to hear the old-school ways of solving problems that never occur to newbies like me!
Thx!
Q
First time commenting — you certainly have an unbelievable talent and your Roamer looks absolutely stunning. We have a similar vintage 39 Avenger in the family in the family that needs a ton of work and I’m both inspired by your work and humbled by the fact that I’d be happy if what I did turned out even a third as nice as yours.
I went back and skimmed the entire project. Are you still in Deale?? I only ask b/c I was taking our hounds for a drive a few days ago and drove thru a couple of marinas on Rockhold creek and saw a tent/shelter that looked familiar.
Best of luck with the complaint against your former boss. I was with the govt for 30+ years and even after they do something wrong (like your boss did) at some point the agency usually sees the light and makes a deal to make things right.
Thanks Michael!
Yes, for now, we’re still in Deale. If you’d like an in-person tour, let me know!
Cheers,
Q
What does the list of remaining things to do look like?
Beauty work as always!
Thanks Bill!
“The list” doesn’t exist, though there’s a range of things that need to happen before I consider it “done.”
Mission critical pre-splash stuff would include welding in new raw water standpipes and attaching the valves and hoses to the Cummins engines, connecting the fuel lines, installing the swim platform, and applying the final coat of bottom paint. But there’s a far longer list of stuff that’d be nice to have done before splashing. If I wasn’t so preoccupied with the claim against my former employer etc., I’d be making far better progress.
Stay tuned!
Cheers,
Q