This must have happened in the dead of the winter of '07. You'll see why further down the page. I made no attempt to follow my chronological nomenclature for the pics, but they're in order of how the work went about.
The first step was to plot out the location and cut the hole in the deck. It's about 18"Wx 20"L. (I haven't measured it lately.) The tools: a trim router with 1/2" square bit, screwdriver for the guide strips, and most importantly, a square to do the very accurate layout of the guides.
The layout marks are there in the circles. You probably can't see them because they're simply lights cuts made with a utility knife.
Two straight strips for the sides, the flat parts of the deck.
Two notched strips to follow the curves of the deck.
This is the dado cut into the deck.
Another view of the dado. Once the setup was complete, the cutting took less than a few minutes. Zip. Zip. Zip. (And zip, ...smartass.)
The skylight is two layers to equal 1"~. The dado in the deck produces a lapped joint at the deck. The two layers, cut to different dimensions, form laps at the corners. Plywood edges can suck up inordinate amounts of goop, so in order to glue up very good corners with the thickened goop, all the edges were coated until they no longer looked starved.
How'd that get in there? While I was working on the skylight, I was also beginning the enclosure of the fuel tank built into starbord side at the transom.
This is the skylight panel oven. Each of the surfaces of the parts waw epoxied seperately. In retrospect I probably could have glued up the layers and then milled the pieces as 1"ers. Less overall chance of busting a dimension. It was awfully damn cold, so maybe my brain was a bit thicker than usual.
First piece goes into its groove. Perfect fit.
First layer complete. No surprises.
Second layer clamped up. Again no surprises.
You'll notice that the sides stand proud by 1/2". At that point the window frame hadn't appeared in a dream yet and I was just covering my bases.
Here we are, completely assembled, deck joints filleted and taped, (first layer - the deck glass will lap up onto this box. And the dream came right on schedule. The window frame will be a completely seperate unit, glued, screwed, and taped to the box.
Nice and tidy.
Here's the toerail drawing. Sometimes you have to get an idea down on "paper" before it escapes. The toerails will extend from the bow cleats to the waist cleats, then again from the waist cleats to the stern cleats. The horizontal piece is the rub rail. The verticle piece is the toe rail. The toerail is more or less just an overgrown handrail - cutout for drainage; an echo of Puffin. The white part is the casing for the thrubolt into the frame stiffeners below deck. A little insurance. I'd hate to be walking on that in a blow and have it fail. To add insult to injury, I'd probably get stabbed with the splinters as it gave way.
This way --> Home.
Got any questions or comments? I'm still "themadmac" only now I'm at verizon.net