We've decided to build a removable hard shell tonneau cover to protect the engine and related parts from the elements while towing.  Normally this could be done with boat canvass stretched over the rear cockpit and fastened around the cockpit coaming with snaps, but we were after a cleaner look without any visible fasteners. (26-AUG-2010)

We built a removable buck supported on the engine stringers.  Cambered deck deams were produced and spaced on every frame.  1" x 2" battens were rabbeted into the deck beams.  The structure will be covered with 1/4" plywood and covered with 10 ounce fiberglass cloth.

When completed, the cover will be cut out to accept the engine and related parts that will protrude through the cover.  We'll be installing the engine and driveline soon, so now is the best time to get this piece completed.  It would be very difficult to build the cover with the engine installed in the boat !

We've removed the tonneau cover from the boat and placed it on our trolley for sheeting and finishing.  Corners were built up from from two pieces of 3/4" plywood molded to a width of 3/4". (27-AUG-2010)

Decking is 1/4" G1S exterior plywood.

The remaining sub deck panels were glued and screwed.  We're ready for fiberglass !  (28-AUG-2010)

Six ounce cloth was applied with West System epoxy catalyzed with 206 Slow hardener.  (28-AUG-2010)

The cover is ready for first sanding and weave fill coats.

The first round of primer surfacer was applied. (04-SEP-2010)

Some of the cover was cut out for the engine opening.  We won't be doing the final trimming until the engine is installed.

Here are a few photos after trimming the tonneau cover to fit around the engine.  Still lots of trimming to do, but it certainly has the look I had envisioned !  It's going to be sweet ! (11-OCT-2010)