Cabin Sole E35-3, Tounge and Groove method. Part 2
Once we had completed the machining, we started with the hatches. We enlarged the openings, width wise, on all of the hatches to match our new machined flooring (below). The forward most hatch in front of the mast was shortened about two inches so it no longer ran under the door to the head.
When placing the flooring in the boat it was important to line the maple strip up with the center of the mast as this was the site line. By measuring from the center of the mast to the edge of the settee and then matching this measurement at the rear most point of the settee, we were able to verify that the center line was true fore to aft. After trimming the hatches openings so that hatched fit and laid correctly in their respective openings, we removed the sub-floor, installed backing material around the hatch openings and then put a coat of epoxy on all sides of each piece of the sub-floor. With the sub-floor installed for the final time, we were ready to start laying out the T&G flooring.
We notched the longest pieces of T&G to fit around the hatches left and right. This gave us a square starting run to complete the flooring port and starboard. We used epoxy and screws on this first run. All of the other courses were glued with epoxy only with the exception of a strip here and there that needed additional restraint. This process went very fast. Matching the odd angles below the V-berth and next to shower pan took much patience and cursing. We used a 3/8's inch strip in these places to create a stop for the end of the runs. All of the other areas were covered with the 1/2 wide trim that we ripped from the new teak boards. Sanding, sanding and more sanding. Teak is soft compared to maple. It was a delicate process to smooth the floor without leaving the maple higher than the teak. When you walk barefoot on the floor you can just feel the height difference. Not an unpleasant feeling.
We used Bona Floor Poly. This is an oil based finish. I really liked working with the product. It went on well and so far it has seemed to stand up to wear and tear (full summer of usage). Ask me again in a couple of years. We applied the first and second coat without sanding. We sanded, 220 grit, between each coat after the second and ended up putting down 7 coats. All coats with the exception of the last was cut with brushing thinner.
The only deviation from the original floor layout was the addition of one hatch directly under the campanion way ladder. This allows access to the outlet/inlets beneath the engine bilge area.
This was a long project but one that has been noticed more members of the family then anything else. Even those that would not notice if we had stepped on to the Queen Mary instead of the Wind Chaser have remarked.
My favorite picture of the project?
This shows the joinery and sub-floor.
Matt
Wind Chaser E35-E #187