Project advice needed

[journeyman]

For a while now I've been wanting to convert the unused space where the aux. tank would be in between the helm seats into usable storage. I have already taken the first step and removed the deck panel and fitted a dry bottom over the bilge. I used marine plywood coated with several layers of epoxy and fitted it with 6" access plates in case I needed to get to the bilge. I also installed scuppers in case, for whatever reason, it got flooded. I made a template of the deck panel for future reference and reinstalled the panel. I then had limited access to this space but it was nice to be able to stow seldom used gear even if only big enough to fit through the factory access plate. The space remained nice and dry all last year so now I feel I'm ready to finish the job.

I just ordered and recieved two Innovative Product Solutions 13x17 deck hatches with drop in tubs. I plan on putting Plano tackle trays into the tubs and free my cabin from fishing tackle which will make the Admiral very happy! The tubs are removable so I will be able to store larger items below. One will be installed over the aux. tank space and one over the area where the head tank and macerator pump is, allowing better access to this system for maintenance.

Since I am not a glass guy, I am going to make it out of wood. The new deck hatches will either be recessed flush or under a second "false" wooden hatch for a flatter, seamless finish. I'm still mulling over design ideas. I was going to use teak but that area is now and will again be fitted with a snap in rug for our "four legged" family member who needs traction while under way. It seems to make sense to use a painted wood. What kind of paint should I use? Should I epoxy the wood and then paint or is there a product that does both?

I'm really excited about this project and hope to have it ready for next month's splash. Advice truly appreciated!!!

 

[NOTHING ELSE MATTERS]

Well, if you use plywood you should coat both sides with epoxy( at least 3 coats or until is shinning), sand until all little dimples are gone, then use epoxy primer, then sand to get it smooth, then paint. I like to use 220 grit sand paper on a 2X4 block sanding by hand.

 

[journeyman]

Thanks for your reply Giorgos! I will be using solid wood for this project but will epoxy before painting as you suggest. I've never gotten the results I'm happy with routing plywood. I'm still at a loss as to paint type/brand. I'm assuming that it must be "special" and expensive (Isn't everything!).

To get me in the water, I will construct this as stated earlier but I've been researching the internet and checking out fiberglass mold making. I figure that sometime next winter I could make a plug then a mold for a deck panel and hatches which have gutters, drainage, recessed hinges, the works! This is usually how I begin a new hobby, which I have quite a few. Anyway, it would be fun trying!

Again, thanks! Hope we're all on the water very soon.

 

[1st grady]

Why not build the box out of HPDE (high density polyethelyne) Machines with traditional woodworking machinery, can be color matched to your hull, will not split, warp or ever need painting. It can be joined using stainless steel screws or "welded". This sink was constructed from HPDE.

 

[journeyman]

1st grady, nice job on that. I'm sure it comes in very handy! I've used HDPE (I'm assuming it's the same as Starboard) and it is easy to work with. I actually gave it some thought but I don't think it's supposed to be used in a structural situations. This deck panel measures 23 X 53 inches and is the only thing people will be standing on between the helm seats.

 

[1st grady]

Using 3/4 or 1 inch thickness you would not have a problem. You could even run some ribs underneath across the 23 inch span. Lay 1 1/2 inch strips on edge on the underside for strength. They could even be "welded" into place. I would not use any type of lumber, it will be a maintanance issue.

Starboard (HPDE) is frequently used for large fish box lids and transom doors.