As this refit moved along I became concerned with the deck to cabin trunk joint, it’s seal and its strength. The decision was made to hoist the Mahogany cabin trunk up off the steel deck, clean, abrade and seal the mating surfaces and re-bed. The cabin top had been of marine plywood and canvas, and is due for replacement or at very least repair and fiberglass, these two jobs seemed to compliment each other thought I did hope to be working on the interior of the vessel this season.

The combination of steel and wood is a poor one, inviting both rust and rot to a party. It took some work to pry, jack and will the cabin trunk off the deck as it had not been removed since construction. The cabin is held to the steel structure with 4 steel corner posts lagged to cabin trunk and with 8 through bolts (1/2″) and 118 screws piercing the 2″ steel flange that borders the cabin trunk aperture. 112 screws had to be drilled out for removal. Those screws were then removed, there holes over drilled and filled with epoxy to accept the new fastener.

The original bedding compound was dried and crumbling, thankfully not too much rot or rust was found though it was present. The steel under the trunk and 5″ out was ground to white metal and coated with three coats of Amerlock. The bottom edge of the 1 1/2″ cabin trunk was sanded clean and the given three coats of West System leading 1″ up both inside and outside edges. The deck will be blasted and painted when the entire boat is done, the cabin and the new joint will be masked off, allowing the blasting and new paint to over lap this new portion.

After much debate I opted to rebed with 8 caulking tubes LifeCaulk a polysulphide from Boat Life. With the slow dispensing tubes I soon opted to cut the end of the tube and use the caulking gun to dispense huge smears onto a trowel. I would buy the trowel bucket next time. I refastened the though bolts squashing out 25% of the bedding compound but filling any and all areas of the joint. I then refastened the trunk with 178 stainless screws.

This shows the new joint, cabin sides and deck will be resurfaced as mentioned.

TASKS IN A REFIT SEEM TO SELDOM IF EVER HAPPEN IN A SENSIBLE ORDER!