Good Old Boat Issue 142: Jan/Feb 2022

Toe-tallyWorth It

Pandemic supply chain issues meant that Chris and Marissa had to use 5½-inch cumaru rather than 6-inch; the result (for now) is that the top half-inch of the L-brackets are visible.

brackets to seal the area between the deck and the base. We through-bolted the bases using 2½-inch-long 316 stainless steel ⁵ ₁₆ machine screws. Finally, we added a bead of Sikaflex to entirely fill the remaining ¹ ₈-inch gap between the bases and the recessed deck edge. The Bulwarks The wood we used to construct our bulwarks was a hot topic aboard for weeks. We wanted to use teak again, but our wallets did not agree, so we researched alternative rot-resistant hardwoods. There were many great options like white oak, purple heart, black acacia, and mahogany, but we finally settled on cumaru, also known as Brazilian teak. We ordered 100 feet of 20-foot-long, 6 x 1-inch boards from Advantage Lumber. On this part of the project, COVID became a factor when the supplier ran out of 6-inch boards, and we had to opt for 5¹ ₂-inch. At this point, we had already completed the L-bracket fabrication and drilling; this would mean that the verticals of the L-brackets would stand slightly proud of the tops of the bulwark boards. Not ideal, but it had taken months already just to get the 5¹ ₂-inch boards, so we decided to live with it. While waiting for the wood to arrive, Chris studied scarf joints to choose the best method to join three sections of wood into a single 42-foot board. He settled on a mechanically fastened, plated scarf joint that would be 32 inches long. Hours went into mathematical equations sketched out on his signature yellow legal pad to ensure the cuts would be precise, since we only had one shot at getting this right, or else we would have to order new wood—and who knew how long that would take to be delivered? Once he transferred the sketches to the wood, Chris used an accu- rate combo square, circular saw, Japanese hand saw, sharp chisels, assorted drill bits, 316 stainless hardware, and marine glue to construct the bulwark plank. With the help of our friends, we carefully maneuvered the heavy, long, and bendy plank to the L-brackets, where I was quick to secure them with C-clamps.

With the bulwark now dry-fitted into place, we stood back and admired how nicely this project had come together. We were thrilled to learn that we would not have to steam the wood to conform to the boat’s shape, which was ultimately a relief despite our elaborate plan to create a steam bag using a thick plastic bag and a turkey fryer for steam. Sixty-four 316 stainless steel fasteners later, we had bulwarks! The wood completed Avocet ’s newly improved look, adding a hint of timeless design to her somewhat more modern construct, as well as an admiring nod to one of Chris’ favorite designers, Lyle Hess. The final pieces were the hawse holes that would replace our prior fairleads, which we felt did not do the overall hull design justice. After Chris sanded, polished, and inset them into the bulwarks, the cast-bronze additions sparkled, beautifully complementing the wood and the boat’s overall look.

When the last hawse hole was in place, we broke free of the docklines that had seemingly weighed us down like shackles and made a mad dash to the Channel Islands so we could enjoy our boat the way she was intended. The water splashed on deck, washing overboard immediately under the bulwark through the slim gap. It was perfect. The bulwark’s height made it easy to safely store jerry cans, fenders, lines, and even the dinghy without the deck looking cluttered. This conversion was a long, compli- cated process, but overall, we are pleased with the outcome and hope that it can inspire others who might be interested in making such a change. Chris and Marissa Neely have been living aboard and upgrading their 1979 Cheoy Lee 41, Avocet, since 2018. Primarily they sail in and around Southern California’s Channel Islands. Follow them at svavocet.com, on other social platforms at @svavocet, and on their YouTube channel called Sailing Avocet.

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