When I did this 10+ years ago [albeit not on a C&C] I used the existing pieces as templates and then dry fit them, sanding any rub points from my less than perfect cuts. All was good. Applying multiple coats of epoxy and then varnish on the pieces, particularly on the bilge board, built up the widths of the pieces so they no longer fit together well. Had to sand and re-coat the edges and the bilge board still rubs. Something a little forethought might have prevented.
The moral of the story is to leave sufficient space on the edges when confirming a dry fit for the thicknesses of whatever coatings you apply. Brian From: CnC-List [mailto:cnc-list-boun...@cnc-list.com] On Behalf Of Kevin Paxton via CnC-List Sent: Wednesday, September 27, 2017 8:41 PM To: cnc-list@cnc-list.com Cc: Kevin Paxton <kpax...@paxdesigns.com> Subject: Re: Stus-List Replacing Cabin Sole - 35MkIII Did this last year on our 34'. Dave and Mike are spot on with everything. Definitely tape the lines where you will be cutting to protect the veneer. I also used a circular saw, table saw, jig saw and a router. Used a hand planner for final tweaking of the cuts. My new lines were not the same width as the old but it wasn't much of an issue. When you trace out the templates it isn't too hard to line everything up. One thing I did that I didn't see mentioned was to drill all holes before applying any epoxy. I also epoxied the whole thing to seal it in completely, then finished with epifanes. I used West system 105/207. The 207 is a clear hardener that won't mess up the top finish. I did about 3-4 coats of each. A foam roller for the epoxy and foam brushes for the varnish. I tried the cheapo chip brushes but continuously got stray bristles everywhere. The epoxy if I remember correctly you didn't want it to dry completely between coats. The varnish I wet sanded in between coats. Gradually getting higher in grit between each. Try to control dust as much as possible. Do this in a clean area where there isn't much traffic. Or surround it all by plastic to prevent anything from getting into it. It was definitely a long, tedious process. But it was definitely worth it. Our old sole was chipping and so deteriorated. But once this went in, it was like it was a new boat. Kevin Paxton 82' 34 Cornfield creek, Pasadena, MD
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