In March 2004, my wife and I purchased Slip Sliding a 1984 Hunter 34. I must say it had a few problems and we were well aware that we going to have a project on our hands. We promised ourlselves that we would live with any major defects. We planned to sail and enjoy our boat for the 2004 season.

In November, I began the task of a sole rebuild for the main cabin (Salon). This involved removing nearly every major system in the boat. The fresh water was located under the port setee, the A/C, and hot water were located under the aft dinette, and the dreaded holding tank (certainly a source for odor) was located under the fore dinette seat. Each of this systems were in sad need of cleaning and repair.

Let me also say that the many members of Sailboat Owners were great to give advice and hints prior to the refit beginning.

Special thanks to Tim Welch of Cabo Wabo, Fred Ficarra of Epitome. Peggy Halls book was an invaluable resource for all things head.

In the Beginning...

This photo shows the Air Conditioner and hot water heater. One major problem with the A/C install was that the cut a major portion of the bulk head (stringer). Instead of properly draining the air conditioner condensate into the bildge it was allowed to drip into the bulk head (stringer) This was another source of mold growth.

Aft View

Here you can see some of mold and dirt that accumulates over 20 years on a boat. When the sole was removed there was thick black mold coating the entire area. Scrubbing and cleaning up was a large portion of this project. When the rotted sole was removed, mildew cleaned, and holding tank on the dock, the boat began to smell much better inside.

Bildge

I listened to a lot of advice before I began this project. I was concerned that the sole was so rotten that I would be unable use it as a template. Tim on Cabo Wabo offered his sole as a template, but in the end I was able to make do with my broken parts and pieces and develop a working pattern.

I purchased standard 1/2 plywood from my local lumber yard. Used the template and cut those to fit. Then, I took the plywood out to the boat and did a test fit. With some modifications from a belt sander the boards fit. The original sole from hunter was fit in 2 pieces. However, these would not fit down the companionway, so the floor had to be done in 3 individual pieces.

I purchased 1/4 Teak and Holley ply from a lumber yard in Detroit. The price for 2 sheets with shipping was 375.00.

My original theory was to laminate the 1/2 ply to the 1/4 and make up the 3/4 floor. In theory this was a good idea, but in reality, there are better ways to do it.

Tim from Cabo Wabo suggested that I purchase the much more expensive 3/4 Teak and Holley ply. That would have been around 210 per sheet, instead of the much cheaper 1/4. But after I purchased my 3rd bottle of Gorrilla Glue and used every clamp in my shop, I would have been money ahead to have purchased the 3/4 sheets.

I still stand by using the 1/2 regular plywood to make all the mistakes. It would have only cost a few dollars if I had to buy another sheet. I should have used them for a template to cut the 3/4 plywood.

This photo shows the lamination process. Using a knotched spreader and nearly a bottle of Gorrilla Glue for each panel. I glued them together with the cauls to spread the clamping force over the entire panel. I oversized the panels a bit and then used my router with a flush trim bit to make them exact.

All the Clamps that I Own

I took the idea from Tim of Cabo Wabo and made one long access board. This will enable us to keep more of the bildge clean. And it eliminated the need for lots of bracing and spliceing under the sole boards. I would definately do this again.

The finish is standard marine varnish. Sanded with 150 on a block between 10 coats. I used a satin varnish because I determined that gloss would heartily show all my finishing mistakes.

2 Panels and new Hatch Board

Here is a photo of the sole, installed. It took a tremendous amount of work to get the systems back together. The pedestals were the easy part.

Installed

Last photo of the install. Note that all the teak and holly bars match up perfectly.

Under Table