19 foot Offshore Power Dory Build #9: Building a Cabin

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Blog entry by English posted 03-30-2015 11:39 PM 6736 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 8: Getting the boat ready for paint, Painting, flipping the boat over. Part 9 of 19 foot Offshore Power Dory Build series Part 10: Completing the Cabin and Building Pilot House »

I have 266 hours in the build so far, and the boat weighs 982 lbs.

Since my last update. I have added a coat Epoxied to the inside of the boat and two coats of Rustoleum Marine paint. This wore me out. The epoxy can’t be sprayed so you have to use brushes and rollers. Working on the inside is much harder on the old body, I don’t work well on these old knee replacements.

Here the tops of the sides have been routed even with the shear clamp.

The next task is to get the foredeck and the gunwales installed. Here I have installed a support at frame Eleven to support the foredeck. I added a little bow to help water to run off.

I am adding supports for the Gunwales and the Inwales. I have installed these so that the Gunwale will be tilted out of the boat forward of the cabin and pilot house the flat in the open area back aft.

Every one of these supports has a compound angle, and everyone is different. There are 22 of them.

The Inwales are installed and a scarf joint is glued up on the boat.

The front wall of the cabin is installed slightly rounded

I was able to route off the excess plywood from the top but had to use a hand saw for the sides.

The top support is rounded both to the front plywood and for the roof plywood.

Next I built the wall between the cabin and pilot house.

Before the roof is installed I ruffed in the cabin Berth and Head. Most of the covers will have hinges installed and the area under the berth will be enclosed will Luan Plywood and used for storage. The berth is 6’ 3” long.

We are going to use a Porta Potty for our Head.

Cabin top side supports have been dadoed into the cabin walls, the center supports will hold a cabin hatch and still need to be dadoed into the cabin walls.

I will continue working on the cabin and build the pilot house. Still have decks and electrical left to go plus fiber-glassing the cabin, pilot house, foredeck and gunwales. I am shooting for June 1 to be ready to float the boat.

Thanks for looking.

-- John, Suffolk Virgina

5 comments so far

View grizzman's profile


7836 posts in 4318 days

#1 posted 03-31-2015 12:33 AM

oh man …my body hurts right along with yours buddy…yep them down on your knees would have don me in, i don’t have any new knees….the inside fiberglass is gonna be a killer…sorry, but i will add you to my prayers….when you take it out, you will deserve that ride….its looking really good john, I’m proud of another buddy here on jocks that i have known that built his own boat...Paul is first….your second…its my prayer that i get to go out in friendship some day…and if I’m ver your way , maybe if i hold my thumb just right , i might get a ride on yours….lol…..enjoy the build.

-- GRIZZMAN ...[''''']

View English's profile


690 posts in 2492 days

#2 posted 03-31-2015 01:00 AM

Grizzman, Any time you are in the Norfolk Area, Let me know and I will take you out.

-- John, Suffolk Virgina

View shipwright's profile


8678 posts in 3813 days

#3 posted 03-31-2015 01:35 AM

Coming along so very well John.
... and I’d be honoured to take either of you out for a sail on Friendship if you get out my way.
I just got home today and I will be giving her a big hug first thing tomorrow morning.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View johnstoneb's profile


3167 posts in 3187 days

#4 posted 03-31-2015 02:04 AM

It is progressing well. I am enjoying watching this.

-- Bruce, Boise, ID

View changeoffocus's profile


467 posts in 2632 days

#5 posted 04-02-2015 12:34 AM

The ship is really starting to take shape.
I feel your pain on working in close quarters but it’s a labor of love. I’ve only spent time doing maintenance on the boats I’ve owned but it was always a pleasure.
I look forward to the next post.

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