Galley Shelf

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(Note Jerry Garcia on the TV
in the background.

The 2001 plan was to make the shelf level with the wood strip that runs along the cabin edge, but I decided to move it up a few inches so that I could hang wine glasses and coffee cups from the bottom.

That created a problem later,
and right now I think it looks
a little odd.
That's probably
just because it's new
and I'm not used to it.

The next step was to make
the little cross piece
that goes between
the posts.

After it was properly fit with a router,
it was propped into place
and a scrap piece of plywood
was set into place for measurements.

The whole thing
is notched and grooved
with a router,
so the construction is solid.

The shelf is narrower on the outboard side
where it attaches to the cabin house,
so that the dogs from the opening ports can swing freely. Teak C Rails are glued along the edges for strength,
and to make another little place to put stuff.

Earlier in 2005
I added a second stainless steel bar
to the galley cabinet.
It's nice to have something else to grab,
but I mainly did it to prepare for the galley shelf.


At the bottom,
it's bolted into the big teak beam
on the corner of the
U-Shaped Galley cabinet.

At the top,
it's stuck into a hole
in the headliner.
I took a little bit of
epoxy putty stick and jammed it up there, and then stuck the pipe into it.

I made little boxes for stuff
on the inboard side of the shelf.

You can never have too many little places
to put stuff.

The cross piece clamps onto the steel posts
with these little blocks of wood.

I used a lot
of clamps
and forced everything to fit.

So it's not exactly square and the corners
don't quite match up.
Big deal.


It's all glued together with Titebond II wood glue.

Here's a pic of the little notches that I needed to cut on the inboard side, so that the rail would fit over the little boxes.

Right about here,
woodworking purists are shuddering
at my craftsmanship.
I don't care.
I want to get this done.

I wet sanded the whole thing with 60 grit (which is like using a grinder)
to get the wood into shape!
That knocked all the corners down
really fast.

Then I wet sanded again with 220 grit
to make it all smooth.

The main shelf compartment
has standard prefab teak rails around the edge, so that I can put lots of stuff in
without having it fall
all over the place
when the boat's heeled over.

I used the bench belt sander
to make the mitered corners.

Usually that works perfectly,
but I did this in the evening after work, was in a hurry,
and sanded one of the pieces
down too far.
Since these prefab pieces cost $40 each, I didn't want to run out and
get another one.

It's finished with Minwax Spar Urethane, which I use for all my internal wood.
With all those nooks and crannies, putting the finish on was a slow process.

I sped it up a bit by making the first coat really, really thin and
just soaking the wood with it.
After it appeared that the first coat had soaked in, I went back with another coat of really, really thin varnish,
and kept applying
until the wood wouldn't absorb any more.
Then after a few hours,
a third coat of normal varnish.

Then I let it dry for two days,
before the first sanding.

All that wet sanding
warped the little blocks that clamp around the steel posts,
so I put some plywood on both sides of those pieces and clamped it in place while the wood dried out,
so that it would dry
in the right shape.


Okay, so Norm over at PBS is never going to invite me
onto his TV show!
I don't have the time, anyway.

On the bottom, there's a small strip of mahogany for cup hooks.

At the far end, there are mahogany brackets for
the wine glass rack.

I put a few coats of varnish on the bottom first, so that I could set it upright and put the finish on the top.

The wine glass rack
is made from Zebra Wood,
because I had a piece of it
in the garage.

It's held on with screws.
I don't know if I really *want* a wine glass rack, and might want to take it off and use the space for something else.

Then I hung it up outside and sprayed 12 coats of gloss and 3 coats of satin finish. I like Minwax Spar Urethane for interior stuff, because it's UV resistant,
and it comes in spray cans. That makes it a lot easier.
Brushing and sanding between coats would have made this job last for another two weeks.

Time to install it.
I left my wood clamps home in the garage,
which made this a bit of a challenge.

The mahogany blocks clamp around the posts
very tightly, and are held in place
with screws and
covered with bungs.


The shelf is also attached to the rails
with stainless steel pins.

A 3/16" hole is drilled at an angle, in one block, through the rail and deep into the next block.

The pin passes through both sides of the shelf bracket,
and the steel rail.

I don't think I'll need to worry about the shelf sliding
down on the rail.


Some of the bungs
match perfectly.

But this one looks downright goofy.

Shucks, it almost seems like
it got *lighter* after it was varnished.

I think I'll drill it out and try a different one.
I can't look at that.

Maybe a dirty oak plug snuck into the batch. Maybe I'll leave it there, so that it will distract my attention from other errors. Maybe I'll take a new mahogany plug and dip it in ammonia
(I just heard of this trick today) and see what happens.

Those two long vertical holes
in the brace are there
to hold lighters.

I dunno, it just seemed like something should be there,
and this was the best
I could come up with.

Now that it's done, I wish I'd made one of the holes into
a long slot, so I'd have a place to stash galley shears.

Oh well. Too late now.

The inboard side has
little boxes to put stuff.

You can never have too many places to put stuff.

I put huge 1.5" coffee cup hooks underneath.

Those are big
insulated coffee cups,
that hold about
20 ounces each.

Don't mess with my coffee.
I'm not friendly in the morning.


The cabin house side is braced
with a teak block, epoxied
to the fiberglass.

On the top, there's a matching block, just to make sure nothing moves around.
The C Rails form
another little place
to put junk.

You can never have
too many places
to put stuff.

Here's the view from forward, looking back.

Methinks the bigger side will end up holding chips and munchie stuff,
which used to
float around the boat.

I need to take a better picture without the big Simple Green bottle in the background.

This pic is my current favorite.

You can never have too many places to put stuff.

September 2005 -- It's nice to knock this one from my list.
It has been on the list for a while. First I had to make the U-Shaped Galley,
then I had to get around to making this thing.