New Teak Panels ~

I discussed in my previous post the installation of the big (sexy) windows and some structural framing that was needed to help support them.

Another reason for this framing was to support the new teak plywood siding that I was building to refinish the interior.

This interior project coincided with the big window install project primarily because the panels that cover the interior sections of cabin top needed to be built before the big windows were installed. It was much easier to get the window holes in the right place by tracing the opening from the outside while the teak panel was in place. It started by building the framing and then making a pattern for the teak panel.  Cutting the panel and then fitting it in place before tracing the hole for the window. Finally the windows were installed and the panels could be screwed into place.

Here are some photos of how it all came together....

This is the stamp on back of the teak plywood I received from World Panel .  I would highly recommend these guys if you're in need of any wood  finishing products. They were extremely helpful in finding what I needed for my project.

Since the port lights were already installed an extra piece was required to make the pattern for these areas. This is the template of the port light shape I made to attach with the teak panel pattern. This extra step added quite a bit of difficulty to this project. Getting the panel cut to fit over these port lights took lots of time, accuracy, and a steady saw hand. 

Here you can see a couple of patterns about to be traced onto the teak plywood. The patterns are flipped over and traced upside down on the back side of the plywood. This assures no markings will be visible on the panel face.  I did the bulk of the cutting here on Dennis's table saw. Without Captain Dennis and Mayhew's Marine workshop this project would have been nearly impossible. Thanks again Capt' D!

Here you can see the patterns taped up to the cabin top and one of the new teak panels fitted in place around the bronze port light. The black plastic was taped up during the inner frame building process to help  the epoxy clean up step. A roll of heavy duty trash bags goes a long way when prepping for some messy work.

There was also lots of cutting that happened inside the boat. Here I am with a jigsaw cutting out the holes for the port lights and windows. When cutting through finish plywood it is important to use good, sharp, scrolling blades. This will ensure that your finish layer of ply does not get chipped or broken. Also it is good to cut with a higher blade speed and move the saw at a slower pace when cutting through the wood panel.

These are the panels with window holes traced on the back side. This would have been impossible with the windows in place therefore making it very difficult getting the holes in just the right spot.

 Starboard side panels before cutting window holes. You can see the forward panel already cut to fit around the port light.

Starboard side after cutting out window hole and mounting panel to framing. 

This is the aft cabin with new teak panels in place and window hole cut out. Should add a nice brightness to this little cozy space. This is prior to installing the big (sexy) window.

This is the galley area.  I think the window framing turned out pretty decent. They still need to be finished off with a coat of paint.  At this point in the project I'm indulging in a nice beverage to celebrate my progress with the interior build.  Next step is to start laying on the varnish...

This is the first area where this project began a couple months prior to this photo.  My decision to go with the teak plywood was simple. I love the look of finished wood, especially on the interior. I knew it would take some extra effort to go this route instead of using a cloth material and I'm happy with the way its turning out.

Looking forward to our whole interior coated in varnish and all aglow... truly making this an amazingly beautiful and comfortable place to live.   I'll certainly be happy to hang my hat in here ~