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To make the cabin top and the deck top pieces
fit really good, we just made up the ribs out of 1/8" thick oak to the radius and exact length to match the boat. Hot glue
is applied to hold the ribs in place so when removed, they retain the exact position. But before removing the rib,we glued
the 1/16" x 1/2" mahogany planks to the ribs to make the outer shell. Once the glues dries, the hot glue can be broken, separating
the finished shells from the boat. Next, trim the edges and sand the outer shells smooth. When the top cabin and deck are
put back on the boat , they fit perfect.
You can notice the thick,heavy piece of
steel holding down the top for the cabin. We laid plasic wrap down on the bench,then applied expandable foam to the inside
of the shells, then flipped them over onto the plastic wrap and used the weight to hold the wooden cabin top down
tight against the ribs. The plastic wrap gives the foam a factory look. This makes for a really nice effect and makes the
cabin top very strong.
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