'86 Overnighter - Rebuilding cabin entrance (bulkhead?)

[nap72]

Hey guys.

I'm gonna rebuild the doors and I guess you'd call it the bulkhead, the wall to the left of the door as you enter the cuddy.

Water rot has ruined the laminated plywood and it's coming apart. (I'm assuming from the leaking window which has been caulked.)

Has anyone done this? I'm gonna use 3/4" starboard. I'm a handy guy and have done alot of carpentry work. Just wondering how difficult, (easy ), the job is.

Thanks.

 

[georgemjr]

Try using the search. Quite a few guys on this forum have done this and I do remember seeing some great pictures of the process and finished product...

 

[nap72]

Tried the search MANY times.

Can't seem to locate it. That's why I re-posted.

 

[Reel Quick]

Just did this to my 89 Trophy Pro along with replacing the fuel tanks and recoaring the decks.
I used 3/4 star board and was very happy with the results.
I found that most of the bolts and screws were stripped and bent when I removed them from the old bulk heads.
ACE hard ware was ALOT cheaper then any other place I looked when I replaced them.
I was laid off at the time so tearing the boat apart seemed like a good idea.
It`s not a hard job,but getting to the some of the bolts were a #%^&*%$#&.I could have used a 7 year old with small arms more than once.
I would suggest you have a bottle jack handy,makes things a lot easier.
Basically,after you get the old one`s out,trace and cut out on the new. Be sure you mark (ALL) the screw and bolt holes.Use a wax pencil.
I had to grind some beavled edges to make the installation easier.You will see this on your old pieces.
Dry fit the new pieces and install your door.Very important.
GW used some kind of vinyl trim around the bulk head that was stapled around the edges.They were all rusted out.
Lord knows why they didn`t use stain less steal staples.
I decided not to replace the trim due to the tight fit when I installed the star board,A clean bead of caulk will fit my needs.It`s worth doing and will last a life time.Hope this helps.

 

[nap72]

Just curious, what's the bottle jack for?

And should I dry fit, then install the door?

I was thinking the door would be the last step.

 

[sfc2113]

I did mine last winter, was pretty easy. I am not that handy. just dont break up the original pieces so you can trace it. I used 3/4 pvc, not as heavy as starboard and was a bit cheaper. Caulked the edges where the the trim was stapled to the edge. dry fit is a must. Holding up well after a real beating last summer and winter.

 

[Reel Quick]

Sorry I lost this post. I just had a new hardtop installed and then it was welded together it tightened up EVERTHING. Bottle jack was used to give a little umph when I needed it,maybe an 1\8th to a 1\4 inch in some spots. Absolutely dry fit everything before you screw. My cabin door fits better now than it ever did......on the trailer...I`m not on the H2O but will be in a month.
Did you start yet?

 

[VeroWing]

I recently replaced the cabin bulkhead on my 22' Seafarer. As stated above, keep old pieces to trace onto new material. I chose to stay with wood, and purchased a good marine grade plywood with nice tightgrain finish. I had some Marinepoxy left over from a transom rebuild, so I coated edges with this, and then multiple layers of spar varnish made a nice finish, that goes well with the teak trim on boat.
I also did not replace the original material edging around perimeter. That was just a water trap.

 

[Reel Quick]

Looks sharp. Well done.

 

[cdwood]

Agree with Vero on staying with the wood.

Vero, any pics of the finished product?

 

[Bob's Cay]

Does any one know how "standard" the bulkheads are on Overinighters? I have an '88 Overnighter and may want to tackle this project someday. What I would like to find is someone with a good pattern they could reproduce and sell, or a pre-cut set of Starboard bulkheads.

It would be really helpful to have something in hand for those of us that might be a little more carpentry challenged.

 

[VeroWing]

Does any one know how "standard" the bulkheads are on Overinighters? I have an '88 Overnighter and may want to tackle this project someday. What I would like to find is someone with a good pattern they could reproduce and sell, or a pre-cut set of Starboard bulkheads.

It would be really helpful to have something in hand for those of us that might be a little more carpentry challenged.

I imagine you may be able to contact Grady and ask them about that. I do know that my brother-in-laws' 1998 Seafarer cabin bulkhead is different from my mid-80s one.

 

[weatherbymag]

bulk retro

I have an 87 gulf stream

has anybody had any luck contacting grady to see if they have the plans.

or are we on our own to trace what's left of the stuff on our boat?

 

[Bob's Cay]

I did get a response from Grady. They did not offer any plans or anything of a standard nature. Grady did say if making a "master" pattern to make it up to an inch bigger to allow it to be trimmed to fit. I got the impression that is how they did it.