Finishing the Interior Renovation (Part 1)

Projects & Maintenance

Having completed the install of the new headliner, mahogany cabin sides and under-deck paneling a few months ago, it was time to finish the interior renovation with the final trim moulding to bring it all together. While taking a break from the interior, I had a chance to look at what had been done and ruminate upon the possibilities of final completed job. If time and money were of no concern, I could easily make this thing look like a gothic church, but those two constraints will help keep the design aspects tastefully unfussy. There were some minor challenges, but I was excited to get started.

Here's an overhead stringer where it abuts the cabin-sides. We need to make that look pretty.

Here’s an overhead stringer where it abuts the cabin-sides. We need to make that look pretty.

My first task was to create some yolk/fiddle pieces to be placed at the ends of the overhead stringers. These would not only cover the gaps between the cabin-sides and the stringers but add some character to otherwise plain lateral transitions. A quick cardboard template was made and transferred to some 1/2″ ply and cut out with the bandsaw. I smoothed the curves with a belt sander and confirmed a good fit over the stringers.


1/2″ ply template cut and sanded.

With the 1/2″ ply template, I grabbed the 3/4″ teak piece leftover from the original drop-down table leg and used some double-sided tape to secure the template to the underside of the teak. Then, with a 1/2″ flush cutting bit in the router I carefully trimmed out each of the final pieces. The router made quick work of it! I had just enough teak from the table leg to get the 8 pieces required. Although will no longer be a table leg, it will remain as part of the boat in a new form. There’s gotta be some good Mojo in that, right?

Too easy!

Too easy! 7 more to go…

After cutting all 8 of the stringer yolks I switched out the flush-cut bit for a 3/8″ round-over bit and carved off the outside facing edge of each piece. The final step was to kiss them with a belt sander to remove the old varnish. The blonde teak grain smiled back at me as if to say, “Nicely done, Sport!”

Voila! I'm getting pretty damn good at this woodworking stuff.

Voila! I’m getting pretty damn good at this woodworking stuff.

Back at the boat I test fitted a few pieces with great anticipation. They were nice and tight! I’ll need to customize each piece a bit depending on the dimensions and angles of each stringer end as planned, but the radii of the inside edges that will hug the stringers are perfect! Maybe watching all those episodes of This Old House as a kid is paying off?



After confirming each of the pieces fit well, and sanding a few spots here and there I began to round of the tops to better match up with the oak battens. I also trimmed the teak stringer faces to allow clearance for the new yolk fiddle pieces.

Final test fit - Rounded off tops and trimmed the teak stringer faces.

Final test fit – Rounded off tops and trimmed the teak stringer faces.

Moving right along, I coated the new fiddle pieces with some Epifanes varnish and installed them. For the time being, I decided not to affix them with screws or glue until the trim moulding is in place. As they are now, the stringer planks press tightly against them to secure them to the cabin sides – they don’t budge. Also, if i need to make adjustments when the time comes to install the moulding, I’m not married to the current placement.

All the pieces are fitting together nicely - Gestalt!

All the pieces are fitting together nicely – Gestalt!

In addition to the fiddle pieces for the overhead stringers, I fashioned some fiddles for the area where the cabin top drops. Not only will they add some boaty panache, but they will also cover a few boo-boos – much like the fiddles for the overhead stringers achieved. I penciled a nice Bézier curve and used the ban saw at the work to make it happen.

Fiddles for the drop in the cabin top made from 3/4

Fiddles for the drop in the cabin top made from 3/4″ red oak board scrap.

Nearly there, once I determined the proper angles I cut the tops of fiddles so they would fit snuggly in place. Then, using the router I rounded off the the edges and used the belt sander to shave some material off the backs to dial in the correct bias. With everything looking good, it was just a matter of drilling, affixing screws and applying some bungs. I’ll hold off on applying varnish until all the moulding is up.




Belaying Pins & Pinrails

Projects & Maintenance

When our DE 32 was first available for purchase back in 1978, several optional upgrades were made available by Down East Yachts. Depending on the buyers preferences…and budget, choices of custom interior layouts, pedestal steering, roller furling, lighting grounding, and just about everything under the sun could be had for a price. One of these original upgrade options were shroud mounted pinrails made to order. Although not terribly necessary for our little boat they do serve a function in keeping the mast tidy by securing all the running rigging while not in use and keeping loose halyards from banging against the mast on breezy nights. But really, they give a boat a bit of that old fashioned tall ship elegance rarely seen anymore.

Functional and Fashionable!

Functional and Fashionable!

With my standard preliminary research I formulated some plans. The pinrails themselves would be a cinch; just two 2 x 3 lengths possibly milled down and rounded off a bit. The main concern was in the belaying pins. I don’t have a lathe, or the patience to whittle such smoothly curved things…and I wasn’t about to bleed out $80/each for fancy bronze castings. As per usual, I had to get creative.

As dumb luck would have it, I came across an ebay listing for “American Made Replacement Handle – Wood File – 5 7/8″ Long” at a ridiculously low price. The dimensions were perfect and with a few modifications I could turn them into strong, good looking belaying pins – on the cheap! I ordered a bakers dozen.

A few cuts on the chop saw...some dowels...and We'll have belaying pins!

A few cuts on the chop saw…some dowels…and We’ll have belaying pins!

The handles came predrilled with a 9/16″ diameter holes down the center and nearly 4″ deep. It was nearly impossible finding 9/16″ hardwood dowel and SS round bar was a bit to pricey for the budget I allowed myself, not to mention somewhat overkill. Additionally, they came with a lathed groove with iron wire wrapped within as some attempt at ornamentation. As curious as I was to see how long that iron wire would last in the sea breeze, I opted to remove it from each handle to begin the project.



Next I lopped off an inch or so off the bases, which gave each handle a more ergonomic length and did away with the recessed grooves all together. That step alone made them look more like belaying pins and less like file handles. Next, I had to widen the holes to accept 3/4″ hardwood dowels. The decision to do so resulted from two factors. First, it was impossible to find 9/16″ hardwood dowels and second, 3/4″ dowels would be much more robust for the duty of belaying lines or halyards with load.

How do we turn this 9/16" hole into a 5/8" hole.

How do we turn this 9/16″ hole into a a larger 3/4″ hole and keep 10 fingers?

Now I needed a way to make a hole ever so much bigger, without complicating it entirely. I considered several options, all of which either required a new tool purchase or a safety risk. With no access to a drill press of any kind I gathered the next best way to bore out the 3/4″ holes was a router equipped with a straight 3/4″ bit. Of course, clamping a round object is inherently problematic, much less plunging into it relatively straight. After a few inspirational beers, I decided I would have to make a jig for the job.


The jig I fashioned was simple and effective. A few pieces from the scrap wood inventory in the back of the truck and a few screws were all the materials needed, well… those and a router which was on loan from my buddy Chip. Beg, borrow, or buy (and quickly return to Home Depot for a full refund) is my motto – but I digress.

One of a kind, prototype handle boring jig. Patent pending...

One of a kind, prototype handle boring jig. Patent pending…

I removed the base from the router and screwed a piece of 1/2″ ply in its place and let the 3/4″ bit carve through to the other side. Based on the location of that hole I scribed some measurements to center the base of wood handles around the 3/4″ hole. I took another piece of thicker ply and screwed in two rails to align and hold the handle firmly in place and screwed that down as a permanent fence. If my measurements were right, I could drop each handle into the jig, clamp it and plunge the 3/4″ bit to the desired depth – one after the other like an assembly line.

"Just a bit outside!" 1/16" off wasn't a big deal, but I took the time to fine tune things to get it as close as possible.

“Just a bit outside!” 1/16″ off wasn’t a big deal, but I took the time to fine tune things to get it as close as possible.

The first handle came out cleanly and straightly cut but the center was of by 1/16″ so I took a few measurements and fine tuned the jig accordingly. I wasn’t all together unhappy with the initial alignment, but it wasn’t a big deal to make the adjustments so the rest of the pins were within 1/32″ or less. After all, what’s the point of making a jig if it’s not reasonably accurate. The anal-retention paid off, as every subsequent handle emerged from the jig within a reasonable standard. The jig took all the guess work out as intended and certainly sped the process along favorably.

Now we're gettin' somewhere!

Now we’re gettin’ somewhere!

Moving right along, I picked up some red oak dowels and test fitted them into the new 3/4″ diameter holes – perfect fit! But before I could cut them to size and glue them in place I needed to determine their individual length based on the thickness of the rail itself. In other words, I wanted the same amount of pin above as below the rail.

Scrap 2" x 3" Pinrail layout.

Scrap 2″ x 3″ Pinrail layout.

Instead of experimenting with a prettier and more expensive wood I procured a few 2 x 3 pieces from the scrap lumber at work and began laying things out. Dimensionally, the 2 x 3 looked just right for a stout pinrail – not too wide but not too skinny either. The lower, inner shrouds where the rails will be secured measure approx. 40″ apart at waist height on deck and angle closer together on their way up to the spreaders. I would have to find the sweet spot in terms of placement, so a 44″ long pinrail was a good starting point. Additionally, I played with the spacing of the individual pins along the rail and found the height of the handle (approx. 5″) spaced between each pin acheived the golden ratio most pleasing to the eye. I marked all the necessary lines and went to cutting, drilling and glueing.

Pieces cut and ready for glue - Assembled belaying pins!

Pieces cut and ready for glue – Assembled belaying pins!

Finishing of the belaying pin assembly was a breeze. I cut the dowel pins to the desired length with the miter saw and beveled each end with the belt sander. While I had the sander plugged in I did my best to roughly plane the handle bases and deburr any splintering from the trim cuts. Add to that some trusty Gorilla Glue and the pins were ready for finish sanding and sealer. Although, I may still round off the handle tops for a more traditional look.

The pinrail prototypes - making slot holes for belaying pins and the grooves for the shrouds.

The pinrail prototypes – making slot holes for belaying pins and the grooves for the shrouds.

On to the rail or rather the rail prototypes, I cut 4 holes in each rail to half depth with the plunge router and a 3/4″ bit (same bit used for the handles) and finished of the holes with a 3/4″ spade blade bit. I had to do it that way due to the bit depth bottoming just shy of the other face and had I only used the 3/4″ spade cutter my holes most likely would have wandered a bit off center. I did however use the first rail with holes drilled and clamped atop the other as a jig of sorts with just the spade bit. Next I had to cut grooves in the ends of the rails which the shrouds run through. Due to the angle an incomplete table saw cut makes I opted to use the ban saw with a terminal point made with a 7/32″ drill bit (one size under the shroud wire gauge. With the terminal points made 5″ inward at each end of the rail I made some ban saw cuts down the center of each rail end to make the grooves. The final task was to drill counter bored bolt holes at each end to insert bolts to tighten and secure the rails in place along the shrouds. With that we were ready for a test fit!

Need to make some minor adjustments...

Need to make some minor adjustments…

Upon placing the pinrails on the portside shrouds it became immediately obvious some minor adjustments had to be made. I think my initial measurement may have been too high on the shrouds and thus yielded a shorter length for the pinrail overall. The rails will need to be extended 4″ overall and the grooves accepting the shrouds will need to be wider. It was key to have something resembling the final pinrails to play with and fine tune before making cuts in expensive wood. I’ll hold off on purchasing some nicer mahogany or teak for the final rails until the next prototype is 100% dialed in. In the meantime, I’m going to drink a cold beer and stare at the fruits of my labor.

A few days later, I grabbed another 8ft 2 x 3 and cut it in half, yielding two 48″ pieces. With the order of operations well established, I bored the holes for the belaying pins, drilled and counter bored the side bolt holes and cut larger grooves for the shrouds.



Although the length was perfect, the larger grooves I had cut where now too big – making the rails impossible to tighten along the shrouds. The final rails will have to have a groove just barely wide enough to except the shroud wires. It may also help to wrap the shrouds where the rails attach with some rigger’s tape or rubber sleeve of sorts to help the rails grip.

To be continued…

A table, a table, my kingdom for a table!

Projects & Maintenance

In owning San Patricio for over 3 years now we’ve come to discover many of the “gifts” the previous owner passed down to us – none of them good. Perhaps the most noticeable however, was the lack of the original drop-down folding leaf salon table. Thankfully, MOST of the pieces were still accounted for, but certain key pieces had been altered to render the table incomplete to perform its task as intended. Simply put, the previous owner decided to remove the table and use it to fashion a shelf over the galley sink…for a microwave.

Now, a normal person, such as you or me would have considered the purchase of new lumber for such an imbecilic project. I could easily forgive such wanton table-cide if it was done in the event of an emergency at sea, to perhaps bolster a window against boarding waves or to shield a volley of flaming viking arrows – I would applaud it! But NOT for a f@%king microwave shelf thrown together at the dock. Release the hounds!!!


Yet all was not lost. It was salvageable with a little reverse engineering motivated by too many dinners enjoyed from our laps. While the table pieces lay in waiting I began by looking for images on the internet of similar tables. With luck I found one good picture from which I could gauge the original inventory, proportions and assembly. This what I had to go from:

Forgive the lack of photo credit...I forgot where I found this.

Forgive the lack of photo credit…I forgot where I found this.

The primary tabletop section to be secured to the salon bulkhead by a piano hinge was about 2″ too short. To restore its functionality I milled a piece of mahogany and fixed it to the business end with wood glue and countersunk screws and bunged the holes. Then with a router I did my best to match the decorative edges from the other unmolested corners. A replacement hinge cut to size aligned perfectly with the original screw holes. We were getting somewhere!


Similarly, the collapsible table leg had also been cut shorter to serve as a support for the travesty that became the galley microwave shelf. It was not salvageable in terms of a table leg so a new piece had to be cut, shaped accordingly and given a clean, routed edge. Not all that difficult really, and I found working with the hand router very enjoyable. The original piece will make fine stock for some pieces of the overhead cabin trim.

As you can see the original piece was way too short to be reused. The new piece is a near perfect match.

As you can see the original piece was way too short to be reused. The new piece is a near perfect match.

The other half to the table seemed to have escaped the sacrilege that befell the other table pieces, but like its counterpart it too had woefully dated formica laminate that was begging for a renovation. I had planned to use real wood veneer, but the expense and durability thereof swayed me toward a fake “Cherry” wood laminate that matched our wood interior pretty well. And that also meant less sanding & varnishing!

Glueing up the new laminate and trimming the excess

Glueing up the new laminate and trimming the excess

Once the laminate was adhered to the table tops I used a few different router bits to trim the excess material and clean up all the edges. Add to that a few hinges and we had something that resembled a working table. The side rails and bottom face can use a coat or two of varnish, but for now I’m calling the job DONE! Goodbye lap breakfasts, lunches and dinners. Plus, the table will provide Jackie with a nice surface for some sewing projects. Winning!

From the stored position the table unlatches, folds down and folds out. It can seat 6 people Jackie's size or 4 people my size. Not bad.

From the stored position the table unlatches, folds down and folds out. It can seat 6 people Jackie’s size or 4 people my size. Not bad.

In closing, I’d like to think the previous owner didn’t fully comprehend the idiocy of her decision to desecrate the original table…but then this is the same person who failed to mention she left 60 gallons of bad fuel in the tank at the time of purchase.  It turned a simple one day boat delivery into nearly 5 days and added expenses and repairs for weeks to come. After all that, she called us a few days later to ask if we could return her $20 boat hook she had left aboard. Ha!

Bless her heart.