New Companionway Boards and Sill

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June 2008 --

There's more to this than the boards.

I don't like the sill, because it lets water in.
It needs a groove, or a lip, or something to block easy water ingress.

The outside teak on the sill is totally shot, with deep grooves in the grain.
It can't be refinished, and I don't have time to rip everything apart and replace it.

I'm focused on function, not form.
I'm going to cover the entire sill with fiberglass and call it a day.

The new sill is made from 1/8" thick vinylester FRP from McMaster-Carr.

Here's the finished view
from the outside.

It's not as comfortable to sit on, that's for sure. However,
it will keep water out.

I should have washed the boat before taking this picture.

Also, I really need to varnish the companionway teak. For some reason, I've left that gray, like when I bought the boat.
I think it has become
one a "final milestone"
to this boat project,
that I would do just before
sailing off in this boat.

I guess that means it's about time.

Here are the new boards.

They're made from Seaboard, which is Tap Plastics'
version of Starboard.
It's a UV stabilized HDPE.

Instead of the old single huge board, this is in two sections.
Now they'll fit behind the companionway steps.

This was so easy, I can't believe I put it off for seven years.

Here it is a few weeks later.

I built up an inside sill,
about 1/4" high, with strips of the same FRP. The whole thing is set in Teak Brown Lifecaulk.

Well, that was simple. On to the next thing.

Because nothing sticks to HDPE,
I didn't try to get really fancy with the joint between the boards.

There's a large three inch piece of 1/8" thick fiberglass, painted brown, and screwed into the bottom board with about eight screws.
I slathered 4200 between the pieces. There should be enough caulk in there to keep it sealed up.

The boards are also cut with a slight downward bevel, so that water won't sit up against the back.