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.