The Gougeon Brothers on Boat Construction - WEST SYSTEM Epoxy

Chapter 26 – Interior Construction 325
Jamb or stop
Rabbetted trim
Epoxy adhesive
mixture (low
density filler)
Plywood
Paper
honeycomb
Jamb
After the plywood-honeycomb
panel has been laid up and cured, it
should be machined and trued. At
this point there are two methods
for bonding on the trim.
Trowel the thickened mixture
into the panel’s edge, filling
the open cavities of the paper
honeycomb along this edge. To
this clamp the oversize trim.
When everything has cured,
plane or rout the trim to suit.
After the panel has been cut
to shape, run it on edge over
the table saw. Set the saw
blade to cut out the core
around the edge without
damaging the plywood. Fit
and bond the hardwood trim
into this rabbet.
Figure 26-15 A section though a door showing the honeycomb
core and skins with two methods of bonding trim to
the panel.
Figure 26-16 A galley in a 30' (9.1m) trimaran with a
bulkhead forward and a hanging locker at lower right.
sailing; in most situations, 3 ⁄8" (9mm) plywood is
adequate. We have successfully used 1 ⁄4" (6mm) ply,
sometimes including minor framing to improve overall
panel stiffness. For large partitions, you may choose to
use the core construction techniques outlined in
Chapter 11. Core construction saves weight and results
in stiff partitions with better sound-deadening quality
than possible with a single panel.
Cabin Sole (Floor)
<strong>The</strong> first part of the interior to be installed is the cabin
sole, or floor, which will be walked on. Plywood from
3 1 ⁄8" to ⁄2" (9mm to 12mm) thick is generally used as the
floor base, with proper support framing underneath. To
achieve maximum headroom, most designers will strive
to get the floor as low as possible in the bilge. This
sometimes causes frustrating construction problems due
to lack of room. We have found that bonding a portion
Planking
Notched to
fit around
bulkhead
Deck beams
Use of a template to determine
shape of cockpit sole
Bulkhead
Figure 26-17 Spiling the shape of a cockpit sole.
Sheer clamp
Spiling block
Brace to
prevent
racking
Figure 26-18 Installing cabin sole framework in Rogue Wave.
<strong>The</strong> structure supports the hull skin as well as the cabin sole.