Building the Glen-L HOT ROD - Deck Page - Page 1
 
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Normally the deck fiberglass would overlap the deck-sheer junction with a two or three inch overlap on the sheer.  This would entail refairing a two or three inch wide strip of fiberglass along the complete length of the sheer.  This is a lot of extra work !  We've laminated two 3/4" wide strips of 2 ounce fiberglass matt to the sheer to form a 'shoebox' flange to which the deck fiberglass will be draped over.  Total area to be sanded is reduced to a 3/4" wide strip along the sheer.  The flange is wide enough to receive a stainless steel rub rail.  (05-APR-2009)

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Click to enlarge. Blocking for the aft stainless steel pop-up deck cleats wax glued up.  (19-JUN-2010)

Click to enlarge. Blocking was barrier coated.

Click to enlarge. Deck sheeting was cut out for the pop-up cleats.

Click to enlarge. Cleat in the 'up' position.

Click to enlarge. Close-up shot.

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Click to enlarge. Deck blocking was added to handle the plywood joint.   (15-JUL-2010)

Click to enlarge. We ran the blocking at an angle so that any hard spots could be spread across a larger area.

Click to enlarge. The front deck panel was trimmed to fit.

Click to enlarge. With the rear deck panels installed, it's time to put a 1/2" radius on the deck ply at the transom.  We bolted two pieces of 2" x 4" through the transom tie down bolt holes.   (18-JUL-2010)

Click to enlarge. We dug out the transom frame template (one of 160 templates we built for this boat !) and screwed it into the two pieces of 2" x 4".

Click to enlarge. This will give us some support for the router.

Click to enlarge. A 1/2" round-over bit makes quick work of rounding the edge for applying fiberglass.  

Click to enlarge. Deck was covered with 10 ounce fiberglass cloth.  The cloth was draped around the radiused 'shoebox' edge.  We had previously built up several layers of fiberglass mat and cloth along the sheer to form a 'shoebox' joint along the sheer.  This deck-to-hull joint is used in fiberglass boats and saves a lot of time as the deck cloth doesn't overlap the hull, only a 3/4" wide strip at the sheer.  (22-JUL-2010)

Click to enlarge. More cloth was applied to the rear cockpit carlings.

Click to enlarge. Cloth overlap will be ground down flush.

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Building the Glen-L Hot Rod : www.kanecustomboats.com      Revised 09-AUG-2010