For quite some time I've been contemplating just how to do the portlight backer boards. I had a general idea not nothing concrete. I was also in a quandary on just how to round the corner from under the catwalk to the cabin sides. The other day it came to me. Create a corner with multiple layers of 3/4 inch plywood. The first board, attached with thickened polyester resin attaches under neath and sticks past 3/4 inch for the first face board to rest on. This also produced the proper arch and curve. Then the second face board is biscuited and glued in place. The final under board will be of 1 inch finish oak and stick out far enough for a safety hand rail to be incorperated with it. (this board in not installed yet in the picture)
Then the port light backer boards are set in place again using thickened polyester resin. The center cutout is smaller than what it will be. When I actually get the port lights I'll cut the finish hole using a template. I'll be using Newfound Metal 7x15 portlights in the main cabin and 5x12 portlights in the forward cabin.
I'll attached Polystrene board between the backer boards and I'll have a great surface for installing the finish oak strip trim. Should look great when it all finished.
This should make the cabin nice and cool when the sun is beating down on it ... and, when I'm in Alaska it'll be nice a cozy warm.
Now, on to the fwd cabin for port lite backer boards and insulation.
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