Delaminated Bulkhead and Painted Trim Completed

[leeccoll]

While my '87 Seafarer is at the shop getting the bottom paint removed, I just pulled the helm trim and doors and bulkheads which were rotting to the core.

Going to see how much it will cost for Starboard in 3/4" using my old cutouts as templates. I don't want pure white, and I don't see the other colors that would blend in better for me in anything thicker than 1/2". At least in my neck of the woods, but I will find out what is doable soon.

If that doesn't work, I will do what UCPA111 did on his grand refurbish and cut marine grade plywood to match existing bulkheads , epoxy, and laminate or paint.

Then I will paint the teak trim pieces to an off white color, matching what I did over the summer in the back of the boat. Should come out nice and clean when it's all done.

 

[Ky Grady]

Love seeing stuff like this. Showing the old girls some love and bringing them back with a refresh.

 

[SirGrady226]

I remember this process well, it was a long road but well worth the effort. Lucky me that a forum member had good bulkheads for sale from a boat he was parting out, which saved me a lot of trouble. I picked up some small starboard trim to apply along the bottom with marine caulking behind it to seal out any moisture from getting to the bulkhead end grain anymore.

 

[DennisG01]

Some other thoughts for Starboard... this is the brand name for HDPE. Other manufacturer's make this stuff, too. Taco Marine, for example. You may also be able to order through a company like McMaster Carr (but shipping may be pricey for the sizes you need). Another product to check into is LD PVC board. If you can find this locally, I would use this over HDPE in a heartbeat. But the least expensive way would, obviously, be wood. And, you wouldn't necessarily NEED marine grade if you're going to epoxy it (especially the ends). It certainly wouldn't hurt, of course.

 

[leeccoll]

Thank you Ky Grady, SirGrady226, and DennisG01 !!

Will be updating this thread as it comes along.

Too bad the bigger projects I did a few years back on her, I did not take the time to document for others down the road.

Today was sanding, gluing split trim pieces, and priming. Still figuring out what I will do with bulkheads and door.

Was quoted $170 each for 3/4" Starboard bulkhead in off white including shipping. I will have to cut to fit. Not too worried about that.

As for the bi-fold doors, I touched base with someone who used to fabricate doors a few years back, but has moved on.

I do not want louvered doors, just not my thing.

 

[leeccoll]

Some other thoughts for Starboard... this is the brand name for HDPE. Other manufacturer's make this stuff, too. Taco Marine, for example. You may also be able to order through a company like McMaster Carr (but shipping may be pricey for the sizes you need). Another product to check into is LD PVC board. If you can find this locally, I would use this over HDPE in a heartbeat. But the least expensive way would, obviously, be wood. And, you wouldn't necessarily NEED marine grade if you're going to epoxy it (especially the ends). It certainly wouldn't hurt, of course.

None of the big box stores stock it or ship anymore. I'm guessing too expensive to transport, and/or not enough small scale consumer demand?
Plan B LOL

 

[leeccoll]

I remember this process well, it was a long road but well worth the effort. Lucky me that a forum member had good bulkheads for sale from a boat he was parting out, which saved me a lot of trouble. I picked up some small starboard trim to apply along the bottom with marine caulking behind it to seal out any moisture from getting to the bulkhead end grain anymore.

You hit the lottery

 

[leeccoll]

Love seeing stuff like this. Showing the old girls some love and bringing them back with a refresh.

Yeah buddy!

 

[DennisG01]

If you want to pursue the plastic...

No, I wouldn't expect the run of the mill box stores to carry it. You might get lucky at a real lumber yard - possibly a real hardware store. Also check with local marinas/boat stores as they would have suppliers to order from. An online place like Jamestown is a possibility, as well as the other one I mentioned.

Edit: You could also check with some boat dealers (pontoon or otherwise) that use plastic lumber in seat construction as this is pretty common with the better manufacturers. They may be able to order you a sheet from the boat factory (from their supplier) and have it shipped along with their next boat load.

Don't forget about looking into LD PVC.

 

[DennisG01]

Here's another random idea if you choose to go with plywood...

One of the biggest problems with the way that Grady originally did is running the plywood so close to the floor whereby it would wick moisture up into it. 4 to 5 coats of epoxy soaking into the end grain will pretty much turn that end into plastic. Or, you could easily build a jig to extend the end of the plywood and pour epoxy into it, essentially adding a 1/2" of length to the plywood in the form of epoxy. The 1/2" epoxy end would of course be the end that goes to the floor.

 

[leeccoll]

Here's another random idea if you choose to go with plywood...

One of the biggest problems with the way that Grady originally did is running the plywood so close to the floor whereby it would wick moisture up into it. 4 to 5 coats of epoxy soaking into the end grain will pretty much turn that end into plastic. Or, you could easily build a jig to extend the end of the plywood and pour epoxy into it, essentially adding a 1/2" of length to the plywood in the form of epoxy. The 1/2" epoxy end would of course be the end that goes to the floor.

Yes agreed, and also could add a strip at the floor of PVC or Starboard to seal it off like SirGrady226 did. One existing bulkhead had totally removed itself from the flooring anchoring screws.

I've decided to go with plywood on the bulkheads. Reno Nevada is a small town, so I do what I can living here. And I have a good idea about using original bifolds to make them updated as per my liking.

Thanks for your thoughts Dennis

 

[HMBJack]

"I've decided to go with plywood on the bulkheads."

Good decision. Boat restoration can be a lot of fun and need not be expensive. Coating the cut ends of the plywood with paint, varnish or epoxy will prevent water wicking. Plywood is what GW used when they built that boat so why change? Good luck and keep us posted. We all enjoy seeing stuff like this!

 

[DennisG01]

could add a strip at the floor of PVC or Starboard to seal it off

Yes, but... you would still get water/moisture wicking it's way into the plywood. Obviously, not as bad as if the wood was directly on the floor. The important part is to fully and completely seal the bottom edge of the wood.

 

[DennisG01]

Plywood is what GW used when they built that boat so why change?

Well, the reason to change would be to improve upon the design. However, if it was my boat, I would probably go with wood, as well. Right now my boat is 38 years old and still has the original wood. If I replaced it today with wood, and got another 38 years out of it... I'm sure my son or grandson would be happy to replace it again!

 

[Stephnic]

You can also check with boat outfitters for the material they will ship it to you. Not sure of the prices but they can also make your bifold door too. Might be worth a call and check them out. I am having a custom tackle storage unit made to fit into where the refrigerator is. Waiting to get the measurements then the price. Good luck with the project.

 

[leeccoll]

"I've decided to go with plywood on the bulkheads."

Good decision. Boat restoration can be a lot of fun and need not be expensive. Coating the cut ends of the plywood with paint, varnish or epoxy will prevent water wicking. Plywood is what GW used when they built that boat so why change? Good luck and keep us posted. We all enjoy seeing stuff like this!

Thanks for your support HMB Jack.

 

[leeccoll]

Forward progress: Cut bulkheads out of 3/4' plywood. Epoxied edges first then 3 coats primer, 2 coats oil based enamel.
Trim is also painted 3 coats shellac primer, 2 coats oil based enamel.The bulkheads I used a roller on the final coat, and got a nice texture on it.
Attaching a close-up.
I was thinking about changing the bifold door style....was quoted $800 bucks + shipping. I guess I don't mind the louvered door look after all .

 

[DennisG01]

Looks nice. I like the texture you got from the roller. Subtle things like that help to keep it from being "sterile" looking. On that note... what do you think about painting the louvers a shade or two darker? Not a lot - just enough to subtly change the look. Just a thought.

 

[leeccoll]

Looks nice. I like the texture you got from the roller. Subtle things like that help to keep it from being "sterile" looking. On that note... what do you think about painting the louvers a shade or two darker? Not a lot - just enough to subtly change the look. Just a thought.

Never thought about that. Could be very cool, but I already had the enamel from painting the trim in stern so I just went with it.
Also might be interesting to paint the door frame a shade darker to highlight the louvers because all the rest of the boat trim will be one color.
I think I'll get it all installed, then ponder, but good thinking!

Edit-Now you really have me thinking.....the good news is I have one more coat to spray on the louvers tomorrow if it's not too windy outside. I'm gonna open up a bottle of wine soon and negotiate with myself

 

[DennisG01]

Never though about that. Could be very cool, but I already had the enamel from painting the trim in stern so I just went with it.
Also might be interesting to paint the door frame a shade darker to highlight the louvers because all the rest of the boat trim will be one color.
I think I'll get it all installed, then ponder, but good thinking!

Edit-Now you really have me thinking.....the good news is I have one more coat to spray on the louvers tomorrow if it's not too windy outside. I'm gonna open up a bottle of wine soon and negotiate with myself

Doing the frame could look good, too. On the other hand... if you keep going with your original plan, you can live with it for a while and if you decide to change it, it's just paint!

I'm gonna join you...