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17K views 53 replies 25 participants last post by  Kentuk55 
#1 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
 

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#2 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
This is looking good!! I am interested to see what is next.

Are you thinking of any way of letting light in?
 

Attachments

#3 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
That is "special" wood and with your layering system it ought to be very strong. I think you made the right call although you probably will miss the light from the acrylic top. Maybe you could incorporate a port hole in your hatch cover.
Whatever…I am so envious!! The Friendship is just so beautiful. Do you need an apprentice boat builder??
 

Attachments

#4 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
That is a better "fit" than that plastic one! And you made it!
 

Attachments

#5 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
The light isn't really much of a big deal. I spend very little time in the cabin with the hatch closed, really only when it's raining or when I'm sleeping. In either case the doors can be open. I also have a boom tent that would keep rain out of the hatch if it was open. No one is ever inside when sailing.
 

Attachments

#6 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Paul,
Still in my doubtful mind is a question whether the hide glue will withstand the heat under the sun. Direct sunlight can melt asphalt roads down here (34 to 35 deg Celsius) tropics. Anyhow, the lesson I learned from you is how to crisscross laminates specially on a curve surface. I just wish to put it in practice. Thanks Paul.
 

Attachments

#7 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Paul: Are all the layers your special cedar.

And is the 1/8" plywood also glued into the sandwich? or is it just the holding the first layer of cedar that is edged glued?
 

Attachments

#8 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Cool, thanks for the details on the cold-molding: I'm formulating a plan to build a bathroom sink using that technique, and want to absorb all the details on the how-to that I can.
 

Attachments

#9 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
That will certainly last a lifetime and then some. Very good…
 

Attachments

#10 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
what a fun project paul, its always great to learn new things from you, i wish i would have gone to a boat building class when younger , so i will enjoy seeing you show and tell…
 

Attachments

#11 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
That's quite a large piece… didn't look that large before…
WOW… that is a real Project!
 

Attachments

#12 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Bert, Heat alone won't hurt hide glue. It must be wet (not damp) as well. ............and I won't be heading to the Philippines this year. :)

Karson, The piece will be three layers of the 1/8" cedar (3/8" thick). It will be cosmetically veneered inside and out which will add another 1/8" but not much strength. The 1/8" plywood is just part of the form.

Dan, You can make almost any shape in the world by the cold molding process. A sink would be an interesting one. I did a bathtub in one of the 36' sailboats I built in the 80's. My best tip would be the S1 sealer. It is one of the former Industrial Formulators of Canada products now sold by System Three. I had the good fortune to know Jim Peters, the incredible chemist / founder of IFC and in my mind his products are still the best epoxies around. System Three bought them out several years ago.

Joe The cover is about 27" wide and 38 1/2" long.

Thanks.
 

Attachments

#13 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Very interesting blog Paul. I have seen cold molding done in Wooden Boat mag. but never in enough detail to fully satisfy my curiosity. Thanks for showing us all the details.
 

Attachments

#14 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Hey Paul. This is fascinating.

So the first layer of strips is just butt joint glued to itself and not the plywood? It seems that way, but wanted to check. Too bad that slow growth cedar won't be seen - but I bet it is a treat to work with.

Yuck about removing staples - seems like there must be a better way of holding the strips in place. What are plastic staples?

Steve
 

Attachments

#15 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Very nice write up, Paul.

Lee
 

Attachments

#16 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
SPalm, we sold the raptor brand of plastic staples that were used when wrapping plastic tarps or covers on
log buildings or lumber being shipped. There is nothing quite as bad as having a nice piece of natural wood
finished and discovering a big rust stain caused by a metal staple someone missed. Paul just added one more
use for them. The metal staples holding those little tags on Trek or hardwood can also be a pain we could do
without.
 

Attachments

#17 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Steve, Plastic staples are the better way. You can leave them in and sand them off. (if the surface won't show)

Yes about the first layer on this cover because it was a solid mold and an even curve. On a boat where the curves are not even it's hard to get the edges to line up so they usually aren't glued in this method. When the second layer is fastened, it draws the first layer pieces even and the glue under it is squeezed into the joint. Better explanation here.
 

Attachments

#18 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
neat stuff…love the details…
 

Attachments

#19 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Fascinating Paul. Looking forward to this one.
 

Attachments

#20 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
Great skills Paul, fun to watch, thanks for sharing.
 

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#21 ·
Cold Molding a Curved Panel

I just got Friendship back in the water for the summer last week and when I was getting her rigged at the dock someone ( OK me) sat on the acrylic top of the sliding hatch. This has been a weak point for seven years since I initially built her and it amazes me that it has taken this long to break it. Cutting to the chase, the replacement acrylic was going to cost $136 and wouldn't be any stronger than it was before. I've never liked the plastic thing but it did give me a little more light inside. Verdict: Make a wooden top for her that you can stand on if you need to.

So here's a shot you may have seen in another blog describing the new marquetry panels in the cabin doors. If you look closely you can also see the duct tape on the acrylic hatch cover. Oops!!

Boat Watercraft Naval architecture Wood Vehicle


I decided to make the new cover the same way the hull is built, in cold molded cedar. This will produce a very strong yet light and quite thin curved panel. The hull itself is only about 5/8" thick so I'm thinking three layers of 1/8" each should provide the strength I need. Here is the light mold I made up to form it over. It's not strong but will stay in shape if it is clamped down while applying the cedar.

Wood Flooring Floor Automotive design Hardwood


With the 1/8" plywood skin in place I re-sawed some of my special old stock cedar into the 1/8" pieces I would need.
Wood Flooring Rectangle Hardwood Wood stain


This is what I mean by "special old stock". I count forty grains in the inch between 19 and 20. Maybe you will get a different count, but you have to agree this is special wood.
Ruler Office ruler Rectangle Font Measuring instrument


The first layer is applied with just a couple of brads at each end and the joints glued. (There's waxed paper over the mold) Tape keeps the joints aligned for a few minutes while the glue tacks up.

Wood Composite material Gas Flooring Wood stain


The second layer is laid up at an opposing angle and stapled down with metal staples. These are removed after the glue has set.
Wood Flooring Floor Hardwood Wood stain


I installed the third layer with plastic staples because I had them and it was such a PITA to remove all the metal ones. I didn't use them on the second layer because they are 3/8" long and would have been a lot of work to sand off on the inside.
Wood Flooring Floor Tool Hardwood


Once the glue has cured any unevenness is taken care of easily by a coarse sanding with a long block. You may notice that each of the layers arches across the curve rather than having one run parallel to the centerline and the other two arc across at 90 degrees. Having all the grain crossing the curve will make it stiffer. You may also notice that I'm using hot hide glue. (I wonder if this is still cold molding?) It is the cheapest and most convenient and I'm not worried about it getting wet because it will be epoxy sealed when complete. Also, it will have no "spring back" when it comes off the mold.

Wood Rectangle Wood stain Flooring Hardwood


That's about it for the structural part of replacing the acrylic piece. Next time I'll get into the aesthetic part.

Thanks for looking in.

Paul
About the light and having the hatch open in the rain. ....
I had the opportunity this weekend to try my boom awning over the open hatch during a shower. It was perfect and it's even high enough that it doesn't interfere with the wood stove.

Water Boat Watercraft Naval architecture Boats and boating--Equipment and supplies
 

Attachments

#22 ·
Cosmetic Veneering

You may have seen this video before. It was made for this blog but I added it to my "Hide Glue for Beginners" one as well. It sort of belongs in both. Anyway skip it if you've already seen it.
When we left off, the hatch cover was structurally finished but didn't look too good. So the next step was to veneer it with some nice mahogany strips These will make the cover look like it was actually made out of the narrow boards necessary to form the curve. I got to use my new veneer hammer.



Once the strips were down the other end needed to be cut off and a strip run across the end.

Wood Flooring Floor Wood stain Drill


All finished up but a little plain. Maybe some banding….

Wood Table Wood stain Floor Flooring


A 1/8" cut across the end in way of the 3/16" band.

Wood Table Musical instrument accessory Audio equipment Electronic instrument


This is my setup to fit the banding. A piece of banding is placed with one edge against the near side of the existing rebate and the jig is fitted tight up against the other edge. Now, when the bit cleans off exactly at the edge of the jig, the rebate will be exactly the width of the strip. Easy ! No measuring !

Brown Handwriting Table Wood Rectangle


Fit is perfect.

Brown Wood Rectangle Beige Flooring


A quick soak with S1 epoxy sealer and it's on to the other side.

Table Furniture Wood Flooring Floor


First the protruding plastic staple nubs are sanded off and all is evened out.

Table Wood Rectangle Floor Flooring


The hammer veneering process is repeated.

Wood Flooring Floor Gas Hardwood


And a coat of S1 sealer. This is one of my favorite products. It doesn't go on all thick and plasitc-y but rather applies as thin as diesel and after soaking into the fibers of the wood, it cross-links for a hardened waterproof surface that can then be finished with what ever you like.

Table Furniture Rectangle Wood Dishware


That's about it for now
. The next part will take place on a nice sunny day when I can bring the hatch home and get this piece glued on in place of the acrylic, some trim added and back on the boat for the night. Next day it will be home again for some sanding and finishing and then … well ..... cast off!

Wood Rectangle Flooring Floor Chair


Thanks for looking in.

Paul
 

Attachments

#23 ·
Cosmetic Veneering

You may have seen this video before. It was made for this blog but I added it to my "Hide Glue for Beginners" one as well. It sort of belongs in both. Anyway skip it if you've already seen it.
When we left off, the hatch cover was structurally finished but didn't look too good. So the next step was to veneer it with some nice mahogany strips These will make the cover look like it was actually made out of the narrow boards necessary to form the curve. I got to use my new veneer hammer.



Once the strips were down the other end needed to be cut off and a strip run across the end.

Wood Flooring Floor Wood stain Drill


All finished up but a little plain. Maybe some banding….

Wood Table Wood stain Floor Flooring


A 1/8" cut across the end in way of the 3/16" band.

Wood Table Musical instrument accessory Audio equipment Electronic instrument


This is my setup to fit the banding. A piece of banding is placed with one edge against the near side of the existing rebate and the jig is fitted tight up against the other edge. Now, when the bit cleans off exactly at the edge of the jig, the rebate will be exactly the width of the strip. Easy ! No measuring !

Brown Handwriting Table Wood Rectangle


Fit is perfect.

Brown Wood Rectangle Beige Flooring


A quick soak with S1 epoxy sealer and it's on to the other side.

Table Furniture Wood Flooring Floor


First the protruding plastic staple nubs are sanded off and all is evened out.

Table Wood Rectangle Floor Flooring


The hammer veneering process is repeated.

Wood Flooring Floor Gas Hardwood


And a coat of S1 sealer. This is one of my favorite products. It doesn't go on all thick and plasitc-y but rather applies as thin as diesel and after soaking into the fibers of the wood, it cross-links for a hardened waterproof surface that can then be finished with what ever you like.

Table Furniture Rectangle Wood Dishware


That's about it for now
. The next part will take place on a nice sunny day when I can bring the hatch home and get this piece glued on in place of the acrylic, some trim added and back on the boat for the night. Next day it will be home again for some sanding and finishing and then … well ..... cast off!

Wood Rectangle Flooring Floor Chair


Thanks for looking in.

Paul
Paul, That looks great. What is S1 sealer?
Gary
 

Attachments

#35 ·
Getting it Done and Installed

My spring shop project is supposed to be a set of marquetry panels of Friendship under sail for the upper doors of my desk. However I've had a couple of repair / renos on the real thing interrupt me, this hatch cover being one of them. Well I'm here today to tell you that it's done and I'm getting back to the marquetry.

Here's the final bit of work on the hatch.

First photo is the old broken hatch with the hundred mile an hour tape holding it together. I've removed it from the boat for a trip to the shop and covered the gaping hole with my boom awning against any rain that may come along.

Water Boat Vehicle Naval architecture Watercraft


Second photo is back in the shop with the new top glued on (epoxy).

Table Wood Hardwood Wood stain Gas


Next up, the edges get new strips to cover the edge grain of the new lid.

Building Wood Table Hardwood Flooring


All set to install. A couple of coats of epoxy and a couple of exterior Varathane for UV resistance.

Furniture Table Wood Wood stain Hardwood


Of course you can't just throw away the acrylic. This little screen will keep the wind out of my face when I'm motoring in bad weather from my spot inside. I can sit on the engine cover with my back against the doors and steer with ropes. The only part of me outside then is the top half of my head. If often thought of a wind screen like this. Now I have one.

Table Wood Flooring Floor Rectangle


Here it is finally installed and ready to go. Now the only thing stopping me from getting back to the marquetry of the boat is the replacement of the bad marquetry I did on the boat (cabin doors.) Good news is that I've finished that too. Bad news is that since I started it in another blog, I'll have to finish it there too.

Boat Vehicle Wood Watercraft Hood


Thanks for looking in.

Paul
 

Attachments

#36 ·
Getting it Done and Installed

My spring shop project is supposed to be a set of marquetry panels of Friendship under sail for the upper doors of my desk. However I've had a couple of repair / renos on the real thing interrupt me, this hatch cover being one of them. Well I'm here today to tell you that it's done and I'm getting back to the marquetry.

Here's the final bit of work on the hatch.

First photo is the old broken hatch with the hundred mile an hour tape holding it together. I've removed it from the boat for a trip to the shop and covered the gaping hole with my boom awning against any rain that may come along.

Water Boat Vehicle Naval architecture Watercraft


Second photo is back in the shop with the new top glued on (epoxy).

Table Wood Hardwood Wood stain Gas


Next up, the edges get new strips to cover the edge grain of the new lid.

Building Wood Table Hardwood Flooring


All set to install. A couple of coats of epoxy and a couple of exterior Varathane for UV resistance.

Furniture Table Wood Wood stain Hardwood


Of course you can't just throw away the acrylic. This little screen will keep the wind out of my face when I'm motoring in bad weather from my spot inside. I can sit on the engine cover with my back against the doors and steer with ropes. The only part of me outside then is the top half of my head. If often thought of a wind screen like this. Now I have one.

Table Wood Flooring Floor Rectangle


Here it is finally installed and ready to go. Now the only thing stopping me from getting back to the marquetry of the boat is the replacement of the bad marquetry I did on the boat (cabin doors.) Good news is that I've finished that too. Bad news is that since I started it in another blog, I'll have to finish it there too.

Boat Vehicle Wood Watercraft Hood


Thanks for looking in.

Paul
I wish I was with you but as luck has it I am in Oklahoma helping family and the storm victims I could use some sunshine.
 

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