We learn as we go..

So I finally got around to cutting out the rot on the forward port corner of the cockpit. Like the corner on the other side the rot extended into the ply of the bulkhead. I removed the Formica lining on the inside and found several interesting things. There was a cut-out in the bulkhead for an instrument of some kind that had never been repaired. Just covered over with the teak panelling on the outside and by the formica on the inside. I could see straight out through the gaps between the panelling so water has been running down against the ply for a long time.

There was another hole about 3 inches in diameter that had been patched - probably a small compass from way back.

I also cut a small square out around where the corner of the seat top outside aligned with. I found that there was some rot inside the ply, but it wasn't too bad. I have soaked it in preservative and penetrating epoxy so hopefully that will, together with stopping the water getting in, keep it from getting any worse until some time in the future when someone will pull it all apart and rebuild it properly.

I have bought two pieces of kwila to make new handrails from. Its a quarter the price of teak and I'll see how it goes. I am making them really beefy compared with the old ones, and will bolt them through the cabin roof beams instead of just screwing them in. Cutting out the first two was easy with a good hole saw. I bought a new Bosch 60mm hole-saw and it cut through the 31mm thick kwila very cleanly, if somewhat slowly to stop my light-weight drill-press from stalling. Ran the router around the edges and they are very cool looking. I still need to figure out the right angle to suit the cabin roof and plane the bottom to suit, round off the ends, drill mounting holes and give a good all-over sand to smooth out the few rough parts.

I have also turned down the heads of some screws a size up and a little longer than the originals to refix the sail track to the mast. That seems to have worked well.

Looking at LED nav lights now, a bosun's chair to get up the mast to fix in place, and thinking about what else I need before venturing across Cook Strait.