20-4 Bartender Part II

Westerbeke engine on hoist, ready to go over the side.	Over the logs.	Easing into position.	Transmission bulge requires sistering cutdown frame 8 with more plywood.	Locating mounting holes; all needed enlarging for wiggle room.
Forward port side holes, enlarged side to side.	Engine on oak/okoume blocks, final. Westerbeke's system allows easy, precise adjustment.	Forward mounting block. Extra plywood added under oak wedge.	Final position.	Couplers: R and D flexible version and shaft coupler.
Hammer man is screamin' happy to have his engine in place, in perfect alignment.	Rudder pivot completed; tiller arm and rudder installed. Very smooth, solid action.	Clevis points towards eventual location of steering cable end.	Rudder, prop installed. Shaft, rudder from Precision Machine, Sorrento Valley, CA.	Exhaust system: combo of hose and fiberglass, "ski boat" muffler. Wet exhaust exits hole near the stern.
Inside of exhaust thruhull and backing plate. Below frame 12 is passage for exhaust.	Final assembly: eight double-hose-clamped joints in all. Two custom elbows.	The first: aft end of the muffler required opening 45 degree connector to 55 degrees with 10 degree offset.	The second: twisted double 90 to port exhaust over to the thruhull. Glassed joint in the center	Twisted double 90. Tack-epoxied, followed by three layers of 6 ox cloth and resin.
Twist angle of double 90 determined using mockup of the thruhull fitting; method courtesy longtime buddy Wirfs.	The final home of the twisted double 90.	Frames cut are converted to removable overlaps. This is frame 9, just aft of engine compartment.	Frame 9 with replacement section installed.	Replacements for frames 9 and 10. Parts removed during engine log placement back in (out of view).
Port and star stringers anchored to frames 6-9 to support the inboard edges of floorboards.	Detail of stringer attachment to frame.	Tank bottoms protected with chafe strips at frame contacts.	Fir crossovers for each tank frame position, curing from epoxy saturation.	Tanks in place, with supporting structure for floorboards.
Raw water intake thruhull dry fit forward of frame 9. Cutting these big holes is pucker time.	Raw water strainer support at 9, seacock just forward and below.	Seacock from above. This brass unit later replaced with bronze one.	Thruhull from below.	And a coarse strainer over the thruhull opening, bedded with 5200.
Raw water strainer in place.	Fuel lines and tank shutoff valves running to a tee on the RWS support; then thru a filter to engine.	Closeup: star shutoff valve and tee; raw water seacock protected by a rag.	Raw water installation finished; gray tee for direct fresh water flushing.	Test fit of fuel filter, sans hoses, atop the engine log.
Fuel plumbing completed, sans chafe protection; main shutoff forward of the filter, low.	Side view of completed fuel and raw water plumbing.	During sea trials, replaced fittings at the T, and at the engine, owing to leaks.	The elbow and the T had compression fittings mated to NPT fittings. My bad. They leaked and were replaced.	Aluminum fuel filter mount, high, between raw water hose and inside of engine box (coming).
Bottom view of filter on mount.	Cuddy area boards for the sleeping surface. Patterns made of lath strips (thanks, Dave N!).	Three sections removable; aft set closed on the port and open on the star.	The open area is for footroom when sitting in the cuddy.	Old guy laid to rest; enough room for a six-footer, barely
Piano hinges inset to minimize their profile.	The front two removable boards. Black circles are recessed latches.	Recessed latch detail (McMaster-Carr) just an eighth of an inch thick abovedecks.	Three-eighths ply at frame 5 defines rear of the cuddy; fir along the outer upper edges.	Curved beams of laminated cedar support the cuddy top. Overkill. Cuddy roof strong alone.
Beams attached to the sides; nailer forward asecures front cuddy panel.	Completed beams, under quarter inch plywood.	The sides get rounded forward of the eventual windshield location. I love making shavings.	Cuddy is in rough form; no hatch access or door cut yet.	Hatch and door cut; cuddy exterior sanded, ready for glassing the top.
Six oz glass wetted out. Razor blade run along blue tape edge cuts glass; then pull the tape.	Filling the weave on the glass, and fairing in the edge of the glass.	A beauty shot, second coat of epoxy. Too bad it gets painted.	Original version of helm in mockup phase. See Part IV for final version.	Steering wheel separates throttle/shift lever and instrument panel; latter will drop an inch.
Extension of sides aft to form coaming. "Batten" is half-inch CPVC pipe, because of spiral curvature.	Clamp up first layer of 3/8ths ply; every clamp in the shop needed to produce squeezeout!	Bozo "clamp" setup is gives some pressure in the center to maintain registration.	Aft coaming lams routed to meld quarter and three eights ply. Three quarter inch lams easier.	Here's why: a thin lam had to be gouged out and replaced , a victim of poor clamping
Oblique shot of completed coaming as boat is turned, prior to engine test (see below).	Steering cable running through frames, chafe protection at each frame, etc.	On to the helm; here are cleats and the bottom frame.	Side panel in place; more cleats.	Both sides, now.
Helm open for easier cable hookup, with steering, instrument panel, and throttle/shift control.	The innards. Tight fits, here and there. Single lever control later replaced.	Top o' the helm to ya! Single lever control replaced later -- see Part IV.	Helm closed; electrical panel left; right an access panel; fuel gauges above later.	Battery Box Details
Battery box, switch, and cables. Check thumbnails for details of installation. Getting close to running the engine.	Overflow tank on a custom aluminum mount. Handy holes in the valve cover made this easy.	Engine test day; temp fuel tank on the starboard side. Second time was a charm.	Filler hose, fuel tank vent hose, and battery box vent hose -- port side.	Vents down low, and filler up top.
Fancy dancy filler cover. Gotta love it!	On to the cuddy access. Sapele perimeter graces opening (here in glueup) and the sliding door.	Downward view of door opening, track below and sapele trim all around.	Door in tracks to port, opening in center. Below ten shots is the door and opening in closed position.	Upper track detail. Lots of room for a slippery plastic strip to fit below, later.
Hatch cover for cuddy opening tricky; must fit tightly over the slider. Test clampup.	Aft end of cuddy access hatch cover in clampup.	Screwed together, in place.	And open, sans plywood cover.	Cuddy access hatch laid open; piano hinge to come later. Latch TBA.
Cuddy hatch closed. I made it too deep, which pushed the windshield forward.	Forward cuddy hatch flips back: a simple box, here open; latches installed on captured bolts.	And closed. Both hatch covers will be bright with 2-part LPU (a marine version of Varathane).	Detail on latches (McMaster-Carr). Reminiscent of the bonnet latches on old time roadsters.	Closed position. Serious closure springs demand 1/4-20 hardware to deck beam.
Windshield time: 1-inch fir stock, lap jointed; corner windows pieces. Lotta compound angle miter cuts.	Parts ready for glueup. Stock is heavier than needed.	Completed windshield framework scribed to the cuddy trunk, cuddy access in closed mode.	The whole shebang; sliding door area painted; the lower track can be permanently glued in place.	Cutting the coaming to the line; a satisfying curve! Framesto be glued in place; glass after paint.
Shaw Blue on the topsides.	And Orcas White above. Starting to look like a boat, except it is stranded in that garage!	Back to the cockpit; port ceiling panel with layout for frames and hose passage.	Port ceiling installed; cleats at the bottom edge will support floorboards	Fuel fill hose protrudes inside ceiling surface; this will get boxed in later.
Supports for aftmost floorboard. Removable for service to steering tackle.	Last floorboard opening; support system aside, ready to go in. Cleats have to be right for solid floorboards.	Rear support system installed. Ready to slap in floorboards.	Saturation coat on side floorboards (8 feet each). A nice sunny day made this a pleasant task.	Overall view of cockpit from the rear; fresh floorboards.
From the front.	Central panel: battery; smaller panels still bare wood. Battery box cover needs latches.