Looks great! I hope it's a perfect fit. So in the end, how did you do the cuts? Especially the rounded ones?
I clamped a straight board as a fence for the long cuts and used an old craftsman circular saw with the finest blade I could find at the local True Value. I used my wife’s old t-square to confirm my pencil marks a few hundred times so sometimes I was measuring in picas and every now and then I would put the template over it to make sure it all still made sense.
I was not happy with my first cut but realized I could rotate the board and start over without penalty.
When rounding corners, err on the side of not taking enough and don’t make a second pass because sandpaper is cheaper than teak.
For the rounded cuts I borrowed a friend’s Bosch jigsaw and practiced on scrap a bit before I dug in.
When rounding corners, err on the side of not taking enough and don’t make a second pass because sandpaper is cheaper than teak.
The plywood width came up about 1/2” short in the settee and maybe six inches short in the galley. For both, I ripped a straight cut along the holly line and made what I’m calling cheat pieces that I will be able to adjust the size of but are wide enough to fasten to the bilge piece. And if I screw up that part I still have plenty is scrap left to redo.