New Door Washboards

Marty's Arcadia 30 - Amoretto, desperately needed some smart new washboard doors, so Marty drafted in his son

Richard to do a transformation. Rather than do a ply replacement, Richard chose to laminate and plane a completed

set of new laminated units. The whole of the project is on Richard Facebook pages - ask Marty if you would like to

get more details.

The old door. Now do you see where this is going?

De-lamination, not pretty!

We start with 8 pieces of 2x6 cedar. Using my miter saw I cut 4 to 12

inches and 4 cut to 18 inches long. Technically I only needed 3 of

each, but I wanted extra in case I messed something up. :-)

All the pieces milled up and ready to glue together, but first a beer! :-)

Gluing it up. I am doing this in sections to make it easier.

All clamped up! I am now checking that it sits nice and flat in the

clamps. This is important so you can minimize any later surface

sanding. The finished door thickness needs to be 1/2", remember how I

cut the boards to 11/16"? This is so I have some fudge factor (3/16")

in board warp/assembly inconsistency I can plane out later

All the boards milled and mocked up (dry fit) together.

The door is two halves. There is a trim piece seen here that prevents

water from dripping into the cabin, I will have to recreate it.

All done, the only two things left are to buy or make a new handle for

the Upper half of the door. And get a proper striker plate for the

lock so it does not ding up the bottom door half.