On this week's episode of Onboard Lifestyle we continue working on the master head door of our custom 435 catamaran sv basik. We finally get to lay down the ...

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we got a beautiful Saturday morning subs

just coming up I've got all the rowers

on the lake and looks like the weather's

gonna be good so we'll get a good

productive dan check these guys out

rain or shine they're on the lake

starting at about 5:00 in the morning

it could be blowing stink out here and

they'll still be out here

got all the teams from around the region

practicing on Lake Union

kind of fun to watch though

there's probably I would say 30 boats on

the lake right now

okay let's get to work

morning guys welcome back to SB basic it

is Saturday

which means I am home and we are

continuing our projects I had to get

some chores done first we're gonna work

on the rest of my master head door so

Till's out there getting set up and I

get to a system today which means that

I'm going to follow him around with my

trusty vacuum cleaner my brew and I get

to play a tool girl good morning good

morning really good to work ready to get

to work let's do this you see that I've

removed the door for the final time

in the master head and I did that

because I have a couple things left to

do

I've made a couple little describe marks

on here to fine-tune this in so I'll

shape that in I'll be happier the

reveals after that but the big thing is

where this night of course is exposed

I'll cut this back crush it back about a

little over half an inch all the way

around this and then I'll inlay a thin

piece of marine grade ply and I'm using

that I could just use epoxy to fill this

but epoxy is heavy

I'm doing everything I can to keep the

slab light here's the material I use

it's an 18 millimeter marine grade

poplar ply I buy it from a local

wholesaler here hardly weighs anything

this is probably not 50% of normal

plywood but I would say maybe 60% the

weight is exactly what we need I did use

a piece of it right here I'll show you

how it turned out remember I mortise

or I filled the mortise right here

foxie that in it turned out great so

I'll do that same thing around the door

I have two little corners here where I

had to knock this radius in I'll have to

fill these as well after that I'll be

able to shape the door router it glass

it and paint it first thing I did was

just marked over about twelve point

seven millimeters you like that or about

a half an inch and I'll make this cut

next thing I do is just take my little

piece of inlay mark this out here

this intersection right here

gives me my angle to mitre that

so now what I do to line it up right

there with the end of the filler there I

can mark out my

and that's my mitre

now that have my little inlay pieces cut

out I need to knock this 90 core back

since I went half inch on this I'll

knock this is slightly over half inch

best way to do that is using a multi

tool or a vibratory saw and it's real

simple just going here can you just go

right along each edge of the night

accord and then just crush it back next

thing I need to do know that that's cut

free is our crush back the core pretty

easy actually use whatever you want I

like to use a hammer and a chisel

let's dry fit these now make sure they

fit

instead it's about

good enough it's gonna be all packed

with epoxy I want to leave it just to

slightly Prout's when it's sand it

smooth I could line it up with this

okay I've got all my little pieces all

cut and staged and ready to be inlaid

with epoxy

but I gotta skip up the cockpit first

you know what that means

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that is how you clean

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okay the next stage is to get all these

pieces epoxy it in I'm going to use a

wet system 105 with a 205 partner and

here watch Ross on life on the mold he

has this fancy epoxy mixer well I've got

one - Ross Glen oh okay and I have five

pumps 205 and thicken please

okay minds that little attitude but it

works just as well here you go thank you

so I can take much of this

because when I wedge the piece in it

displaces all of it and squeezes it out

so I just like to get a nice even coat

top and bottom it's going to push most

of it to the back of the cavity okay

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everything's epoxy it in will let this

cure overnight

then I'll be able to sand it smooth

now we're gonna take a little field trip

and go pick up the glass for this you

ready

let's go

let's get some glass let's go

okay heading down to tap plastics pick

up our fiberglass flaw I don't like to

keep too much on board so I just pick it

up as we need it plus it gives us an

opportunity to get some steps in we

don't like we don't like driving very

much in the city just because parking

sucks it's a nightmare sucks but this

also gets us an opportunity to just talk

and get some ideas and bounce the ideas

around brainstorm get our projects done

Plus Emma's gone right now she's at a

friend's for a birthday party we're

gonna pick it up later tonight but this

gives us enough to me

- quality time together

this is quality I'm just kidding

okay tap doesn't close for another two

hours so but the beauty of being on

South Lake Union is there's always

something going on so we see a lot of

activity here so we're gonna go check it

out take a little detour I know the

sun's out

looks fun boats everywhere let's go

check it out

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wasn't it

though

all this all this history down here it's

crazy not only that but it's this place

and just take a break for checks go

check this out

I mean how cool is all this

and we're here ready

okay we got her claw

and hand-holding I'll carry it don't

worry they do need to work out and we're

heading back to the boat time to go pick

up Emma and we got a little detour it

was fun it was nice nice to get away for

a minute and good morning

kind of a blustery rainy day on Lake

Union I just dried out the cockpit try

to dodge a couple of these rain showers

to get some work done so now that the

epoxy is all cured I'll do my final

shaping

just get all this detailed in then I'll

be able to router a nice radius on all

the door edges

oh this weather just sucks

I'm just battling in between rain

showers missing having a enclosure now

door is all shaped in now everything's

been filled and ready to be routed with

one exception it remembers my hump that

was on this side it's not real apparent

but I've had to ascribe this door around

the hump you can't really tell by

looking at the door but look what

happened remember my mahogany inlay as I

had to scribe around that hump it

exposed the night of car so now I'm

gonna have to ditch this all out and put

a filler in just like this

just set me back a little bit I was

excited to get some glass on this today

but look at this mess I got going I mean

it's just a sloppy mess out here today

oh well gotta keep pushing I have just

shred in this cockpit Oh

Glenn's gonna kill me okay got my little

inset here now let's just get this 90

core out of the way so I get it epoxy

Dan I didn't want to bore you with all

the steps it takes to inlay this but

there it is it's all in and now I'm

finally ready to shape this edge that's

the last step everything sanded and

shaped in will round over the edge do a

nice eighth inch roundover and then

start applying some cloth probably you

tomorrow this weather has been kicking

my butt today been dodging running in

and out how does these rain showers I

really should get a enclosure here huh

someday

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okay just finished and here comes the

rain again starting to hit the work got

to keep it dry

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I think that's it for today it's been

tough today

I think I'll call it

and just like that the rain has stopped

and the wind has picked up we got

Whitecaps on the lake today

but that's not gonna stop me cockpit

feels nice

I'd ride it all out we're gonna lay some

glass

so now that the door is all shaped in

all the reveals have been triple checked

I'm gonna lay cloth over this with wet

system epoxy I'll lay this side today

flip it and lay the other side tomorrow

so let's get on this this wind is gonna

be a little challenging but being a

little adventurer as well what I did is

bought a 50 inch piece of glass cloth

and cut it in half so I had two 25 inch

rolls I just cut the entire roll in half

that way I could just roll this out I'm

trying to mix my epoxy here out of the

wind I don't want this thing toppling

over epoxy is all mixed up what I'm

gonna do is get a nice even coat over

the entire door first let it soak in a

little bit and then I'll be able to lay

the cloth down it's my favorite tool for

laying down epoxy just a quarter inch

nap wienie roller can't play around with

the right ones

find one that doesn't shed but once you

find the right one it works real well

I pull the epoxy nicely doesn't drip

and you're able to just lay out a nice

even coats with it I'm gonna lay this on

a little strong right now because I want

it heavy enough that when I put the

cloth down it tax fast in this wind

I'm going to do the face and all edges

right now

so it's gonna be a three-dimensional

it's gonna wrap all the way around

this and then when I flip it I'll do

this the opposite that way I'll have to

laminations on all door edges okay now

that the door has a nice even coat of

West system on here start laying out the

glass clock

I work about just segments of this get

it tacked down nicely

it's gonna take quite a bit more resin

on here this was five pumps to wet the

surface and I would assume it's going to

take four or five more to saturate

just a matter of pullin and working this

get all the wrinkles out

okay it's laying down nice

I want to wet this entire surface a

little more just so the wind doesn't

pick it up while I'm working on the

other half I'll have plenty of working

time it's only 60 degrees out I'm using

a fast hardener but it'll still give me

an hour of working time here because I'm

working my way across this

you can see it wrinkle up that's why I

like this the weenie rollers you look at

this I could just roll it out and just

kind of work these fibers and pull it in

the directions that I want without

damaging the cloth and this lays it

right down but here's a big wrinkle

right here I just tug on it put some

pressure on this side of it and then

roll it right out that's one way to do

it the other way is actually pulling

fiber you can give it a little tug right

here to get larger wrinkles started

now see there's some wrinkle here as

well I can go all the way to this end

and give a little tug here way down here

to pull some of this out see that

then just work it tell it lays down

just make sure you're using the right

hardener so you have time to do all this

don't try to rush it

I also mix smaller batches if I think I

need 12 pumps or 15 pumps to do a

project I'll mix it up in three smaller

pods that way it extends my working time

okay I'm wrapping this cloth all the way

down around the edges and the best tool

you could use for this is patience you

just got to keep working it the fibers

will lay down see this as I come around

this radius you just kind of take your

time kind of feel it as you come around

you'll start to learn how each different

cloth reacts a little bit differently

see how I just kind of bundled up right

there

just kind of work it a little get it to

lay down I want to do the edges I'm

doing the face and all the edges on this

poor on a door the edges one gets most

the the knocking around some light uh

two layers there and just one layer on

the face I mean I could keep

over-engineering this and multiple

layers on the face but I'm trying to

keep this light plus this little trick

I'll show you tomorrow by bringing this

down I'll be able to cut this off I'm

gonna leave this wild right now I'll

actually trim this tomorrow morning

after it cures and sand is smooth hiding

my seam right on an edge so when I lay

my other face it covers it right up okay

I've got the cloth all laid down here

looks good call the edges are fully

wrapped

it's what I like these big sweeping

radiuses on the doors how I could wrap

it without having to to cut the glass

and have multiple seams trying to get

around these edges but when you have a

90-degree corner you have to wrap the

seam but all I do is when I cut it I

wrap it so it's on the bottom of the

door so if you do see a little bit of

imperfection it's gonna be unseen can't

let this cure for a little bit it's kind

of a blustery day hoping for no rain

I think it'll hold off this wind is

killing me though and just like that

it's the next morning and it's kind of

showing the season out here fog rolling

through temperatures 10 degrees cooler

than last night are than the night

before got down in the mid 40s dew on

the decks with these little mayflies

everywhere

I don't mind this time of the year

unless you're trying to get something

done outside

but I gotta get this door finished so I

ended up doing soaring it in the nav

station to cure overnight actually it

kicked off before I put it in last night

but I just wanted to make sure got a

nice bake on it so we'd be flipping that

today a couple hours as soon as that fog

burns off and thanks drew out a bit

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now that the fogs all burned off is

pretty cool watching that burn off this

morning

let's get time to set up feeling much

better about the weather today no wind

there we go so I'm going to do is trim

this up sand the edges and lay the other

side that's my goal for this morning

give the time for this to cure up today

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here's something I really like to do

when I wrap this class cloth I ended it

on this edge here and this is a nice

eight inch radius now I'll just sand

this out which will hide this scene

because the next one come over and come

to this edge then when I sand that out

it hides that scene this way I'll be

able to you know build this whole door

glass it with zero faring compound my

seams will be hidden on the edges you'll

see it'll turn out real nice

that didn't take long maybe 15 minutes

of hand sanding and get a nice tight

shot of this look at this I mean you

can't even feel it with your finger this

seam is 100% hidden on this radius now

so now when I lay this glass cloth it'll

cover that seam come over to this one

then I'll do just the opposite feather

on the opposite side now let's lay some

cloth

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okay glasses laid down

nice and flat

let this cure for a couple hours well

probably bout six hours and we'll bring

it in for the night so I could stand it

tomorrow morning okay just like that

it's a new day it looks like a good day

look at this no wind no rain just nice

Sun couple clouds it's beautiful on the

lake in my project today now that I've

glass on all sides do my last trim ease

this edge with sandpaper and then stand

out this whole surface you can see in

the reflection of the Sun the texture to

the cloth that's going away today

I've been sanding for about an hour and

15 minutes now on the slab a hand sanded

all the edges and then I used my orbital

with a real coarse grit and the trick

I'll show you the trick but look at this

I mean this is just baby smooth now you

try not to burn through anywhere and I

didn't so I'll show you how I did that

let's look at this other side here's a

course it starts out so what I do is I

use an orbital and I work the perimeter

of the slab first because that seems to

be the hardest any hardest the sand the

easiest to burn through you do not want

to burn through so you just take your

time and just keep working the door nice

even strokes to factor forth back and

forth I'd like to run the perimeter

first and then work the field and just

take your time you do not want to burn

through if you burn through you're gonna

have to do a repair or use varying

compound to the picture burn through so

nice even pressure and

the outcomes gonna be nice

takes a little practice though I am

almost done sanding just a little bit of

touch-up here and there and then I'm

ready for paint

well at least primer take a look at

these seams this is actually a seam

right here I mean you can't feel a thing

you can't see a thing everything just

feels like glass didn't burn through it

once that's the key let's paint this up

see it looks like

okay The Doors got a nice coat of primer

on it and hang this right now before I

get too far along on mortise for the

handset see how it fits

okay the door is hung let's take a look

at this thing looks good let's take a

look at these reveals reveals are

looking nice quite a bit left to do

though I stuff to put a door stop on

here need two more to send the handset I

also need to put a catch on the backside

so the doors in the open position it

locks in the open position but while

it's locked

it covers up the light switch for this

room so what I'm going to do is move

that light switch now out here so as you

enter the room you switch it here it

turns on the room so I get quite a bit

to do but it's getting there I'm gonna

have to start tackling some of the stuff

tomorrow

sorry it's getting light and it's almost

time for dinner come back next week to

see one of our cool videos remember to

leave a like and subscribe see you then

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