With the cabin trunk rebeded it was time to look at the coachhouse (cabin) roof. The original construction consisted of two layers of 1/4″ spruce ply screwed to the 1×2 oak frames. That sheathing was then sealed with a layer of canvas saturated in carpenters glue.

The state of the original roof was fair but felt somewhat soft underfoot and I wanted to inspect.

The original roof was painstakingly removed and used as patterns. I found that the two layers of spruce ply had no adhesive laminating them together. The original 36 plated screws had corroded badly, and water intrusion was obvious in the trunk-roof joint

The new roof consists of 2 layers of 6mm marine plywood laminated together, and firmly cemented to the cabin trunk, with thickened West System epoxy. The two layers were then sheathed in a layer of 10 oz fibreglass cloth set in epoxy once again. The roof was then faired with subsequent coats of West System. 132 stainless screws fasten each layer to one an other, and to the oak frames and mast step.

The forehatch aperture was prepared for the new plate aluminum hatch.

A source of some aggravating leaks had been the seam in the cabin trunk where it reaches its tallest. I ruled out injecting epoxy and decided to route a slot along the length of the seam 5/16 deep, pack it with thickened epoxy and a mahogany strip, to be sanded flush. Here are some process pictures.