Pilothouse

Clean hull ready for here own single bedroom apartment addition...

Starting the Pilothouse Structure...

Now that the Redwing is right side up, we are on to the construction of the pilothouse and begin to see Miss Addy take shape.
the hull had to be cleared of all bracing and 100's of screw tips ground down inside the boat.  A lot of the screws were long and fully penetrated past the parts they were joining.  I also had to trim the keel bolts that stuck up from below and smooth those out.  Now that the prep work was done it was time to cut some plywood!

Plywood clamped together, Marine Fir facing up.

The sides of the pilothouse are actually a laminate of two sheets of ply, 1 - 1/2" sheet of marine fir and 1 - 3/8" sheet of yellow pine bead board.  Laying out the plybead facing down I crossed the two sheets of marine fir, oriented 90 degrees to the underlying plybead.  I clamped the pieces around the edges and laid out full size patterns that I had plotted out to cut by.  It could have been laid out on the board easily since there isn't any complicated round bilge to cut to but this made it just a little easier to position the door and window cutouts without a lot of extra measuring.

The plotter was only 36" wide so we had to use match lines
to join them together.  Lead filled shot bags holding the
prints down... thanks Brad!

Finished Pilothouse Back Wall Bulkhead cut out and ready to glue up

A homemade saw guide and hole cutter started the door opening.
Note the bead board facing up

Now that the parts were cut, I used a copious amount of PL Premium adhesive to join them together along with 5/8" narrow crown staples.  This is all above the waterline and am basically just adding a decorative interior finish to the pilothouse anyway with the beadboard installation.  I could have constructed the pilothouse out of 1/2" and added the ply afterward but thought I would kill two birds with one sawcut.

A pair of finished cabin sides ready to install.

Assembly...

Station 16 Bulkhead

the assembly proved one important point that had nagged me since we laid out the stations and that was, "How square had we managed to keep it?"  The pilothouse sits between Stations 8 and 16.  My wife and I, diagonal measuring team from way back, pulled measurements from frame to frame and found a 1/16" difference.  the true test came when these walls went up...

First the back bulkhead...  It fit well and we secured it every 6" with 10 x 2" 316 stainless steel screws.

Then the front bulkhead, secured in the same manner at Station 8.  So far so good.

Front Wall and rear wall installed

Side walls in place.

We tied them together for now with 2-1/2" stainless pocket hole screws on 8" centers.  They will be epoxied and covered in glass when complete.  I ran out of time to cut the windshield and am glad I did.  I had originally designed a solid, one piece windshield.  I have since decided on a two piece split windshield.  Smaller glass and prettier I think.  At least more retro than the single piece windshield.
I am sitting in my living room getting ready to post this and have left it unpublished for weeks until the windshield is cut.  My plywood cut table is outside the shop and it has been extremely rainy in Georgia.  We are waterlogged this year, so I moved on to other things and just haven't got back to the last windshield panel.  Decided to go ahead and publish this to keep true to the actual sequence of events.  At some point you guys will see the panel magically appear, but for now, I will hit the "Publish" button and on we go!

UPDATE... 4/12/15

With quarter round installed

Notch to be filled

The windshield panel is in.
Using shop made 7/8" yellow pine quarter round, we epoxied a piece to the inside edge and attached the windshield to it. We then epoxied in the same size quarter round to the outside notch that formed the rounded windshield piller support. The overall effect is a nice clean rounded corner with plenty of extra support in a fairly small profile.
The windshield has a large area below the glass that the cabin deck will fall against.