Day 74, 1/1/23 Shower walls to walls glassing. (make shower pan as sower pan) - 8 hours

 Interior, Head, Shower

One more thing to do before final makeup.

One more thing made to fail in time. By design head walls  mounted the way where the plywood edge sits in shower pan. 

What it means? In means main bulkhead and Head walls will rot in time if you use shower frequent. To prevent it you have to use a shower but not put a drip on walls and prevent any level of water on the head floor. Is it possible? Sore not. Then you have nice smell, rotted plywood e.t.c.

So, I decided to glass all walls to shower pan and painted walls with topside two part Interlux paint. It will be good training to learn how to paint topside and deck.

How do I do it? 

Step 0. Dig out rotted wood. 😉

All bottom part of the main port-side bulkhead appeared rotted to trash.

My plan - put 4 5/16 bolts to secure bulkhead to internal-liner structure, cut out all trash and then, make several teak wood blocks in size and make couple support plates to take vertical load from bulkhead to floor. However I know floor is not structural, so likely no sense in support, maybe better to leave bulkhad hang on internal liner.
 

 

Step1. Sand connection area on the wall, to remove melamine layer and get to original plywood  and sand though gelcoat on the internal cabin liner to be able to glass to it securely.

 

Step2. Filled big gaps with foamed polyethylene foam to make some support for filleting. Not structural.

Step3. Using thickened epoxy make a nice (or pretend to be nice 😉) filet.

Step 4. Put  layer of glass cloth. To eliminate cracks in a future. 

 

Couple more steps for the next days.

    Step 5.  Put filler in connection imperfections and sand the fillets

    Stem 6. Prepare all surfaces for painting and prime and paint all.

 

Some cosmetic repair, maybe little structural

As you remember i had a crack on the floor next to compression post. as soon as i removed rotted part of bulkhead i get access to both sides of this crack, I get it grinned out for about 4" to rebuild rib on the floof.

 

It is very interesting, right where crack was i can see difference in color on fiberglass, looks like part under compression post has no glass or made from another type of resin. 

Then I built this area back.