1969 Chris Craft Roamer 46 Refit: Installing the OEM lights On The Aft Deck

Dec19

It is such a pleasure coming up the ladder to the aft deck and NOT seeing ceiling frames or insulation. That Whisper Wall headliner makes a YUGE difference not just in the appearance of the aft deck…it’s good for the soul. The IMTRA LEDs and Infinity Kappa speakers are very nice, too, but I still need to wrap up the OEM light fixture upgrade and install.

I’ve been trying out different kinds of LED lighting, from the stick-on strip lights you can buy on Amazon that I used for engine room lighting, to 12v ‘corn’ LED lights on ebay to replace incandescent bulbs in OEM fixtures in the salon. What I learned from my ‘temporary’ knockabout boat, a 1968 Chris Craft Commander 42, is that the corn lights cannot tolerate heat. The OEM fixtures on our Commander are open-ended on the bottom, but there’s no way for built up heat to escape from the top. So they cook. Which is fine for glass and metal incandescents, but these LED corn lights are in plastic frames that melt and twist and eventually fail long before their claimed service life is up.

So…if you upgrade to corn bulbs in your OEM fixtures, make sure there’s a chimney hole or two…or more…for the heat to escape.

Ventilated OEM Chris Craft light fixture

I stewed for ages over how I’d protect what I thought was chromed steel if I drill vent holes in the reflector. This is a boat, and rusted steel doesn’t reflect light quite as well as shiny metal does. Imagine how surprised I was to find out that they’re just stamped aluminum.

With the corn bulb in place, you can’t see the holes…not that that matters

Oh, and the missing section of OEM cork gasket…that’s the air intake. I didn’t plan it that way, but from a physics perspective if there’s a chimney vent for heat there has to be an inlet for the cooling effect to work efficiently. Also, for these fixtures, 10w corn bulb LEDs are as bright as you can go. the 12w and 15w units are brighter, but they’re too wide and stop the glass and stainless trim ring from closing.

Upgraded OEM light fixture installed at the helm station

I like it!

The aft switch is for the IMTRA LEDs.

This is making me very happy!

Now for the aft-most OEM light fixture to fill that last hole

This fixture was in slightly rougher shape, so it got the full Collinite 810 treatment

The ‘air intake’ gasket gap on this one is slightly larger

Think of it as better cooling…like an intercooler for an ultra high-tech LED light upgrade…not as a brittle, busted up cork gasket.

Ready for showtime!

NICE!

That wraps up almost all of the aft deck headliner work. The only thing left is installing the One-Mile Ray searchlight controls, but that can happen much later. But I still have some mahogany panel work on the aft deck that has to happen if the plywood stack is ever going away. When the plywood stack is gone, the project should be done.

Next up in our 1969 Chris Craft Roamer 46 Refit: Helm Station Side Cabinets

Next up in our 1969 Chris Craft Roamer 46 Refit: Salon Headliner Install II

Aug27

The salon headliner installation is moving right along. We got three panels installed on Day One. Day Two went smoothly, with two more panels installed. It looks absolutely great! But I also had to deal with a climate-related epoxy mess.

It’s been hot in the tent

My tent is great at protecting the boat from the weather, but the plastic skin is also really good at holding in heat. When it’s a beautiful day outside, it’s roasting in the tent. And the higher you are, the hotter it is.

When we were installing the aft stateroom headliner, I moved a bunch of supplies from the work space to the salon. I’d never had a problem with epoxy spilling from its container before, but apparently moving it from the relatively cool floor of the aft stateroom to the hotter salon floor was enough to cause a problem. My theory is that as the air in this 1/4 full can of West System 207 hardener heated up, it expanded and pushed the hardener out of the pump. What a mess! I’ve never had this problem with US Composites epoxy.

While I was cleaning up the epoxy mess, the headliner installer was busy at his craft.

First, he pushes the headliner into the track in a few spots

Whisper Wall Ostrich Gelato is pretty stuff

Pulled up and tacked in place on the forward edge

First, push the material into the track with the spatula edge

Then push the spatula handle forward and roll the material into the track

Rinse, lather, repeat

The final stretch on the first panel

I got out of the installer’s way and came back the next day to find two panels installed. Ready for lights!

First, feel around for the soft spot

Hold your breath and stab through the new headliner

Cut the hole in the headliner, then plug in another new Kai LED

Springs snap the Kai LEDs in place in the 1/2″ plywood panel behind the headliner

Nice!

The OEM light fixture hole is much bigger

10w 12v corn LED bulbs work well in the OEM light fixtures

Then I installed more Kai LEDs

And that’s a wrap for the day

There are three more rows of headliner to install and the salon will be looking much better.

Next up in our 1969 Chris Craft Roamer 46 Refit: Wrapping Up the Salon Headliner Install

1969 Chris Craft Roamer 46 Refit: The Salon Headliner Install Begins!

Aug22

Well…this has been a long time coming. The salon headliner installation has officially begun.

I do like it when I arrive at the boat and find contracted work competently done

That Whisper Wall Osterich Gelato looks outstanding

Thinking back on what a hassle it was getting those LED mounting panels installed at just the right height…it was well worth the effort.

The leading edge turned out great!

Next, I took out my razor knife and started slicing and dicing the new headliner.

Cutting holes for the Kai LED lights

Another light hole and one for a speaker

The recessed Kai LEDs use springs to hold them up inside the 1/2″ plywood mounting panel

New Kai LEDs and an OEM light fixture for the galley

These 10w 12vdc LED corn bulbs are the biggest that fit in the OEM fixture (75w incandescent equivalent)

I found these lights on ebay.

AND THEN THERE WAS LIGHT!

That OEM fixture was on the boat since it was new in 1969. My research concluded the boat went on the hard back in the mid-80s and didn’t move until I found it in late 2007. I didn’t power up the 12v breakers until December 2018. Which suggests that this fixture hasn’t turned on in something like 35 years.

I had a big ol’ grin on my face when it lit up. It’s funny, the stuff that makes me happy.