In this week's episode of Onboard Lifestyle we start a milestone project that is long overdue. We have made four interior doors on our custom 435 catamaran s...

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everyone welcome back to SB basic you're

probably wondering why I'm standing on

this piece of wood on a boat that is

mostly synthetic actually the

superstructure

on our boat is 95 percent 90 core and

about five percent wood there is a

little bit of wood in areas where

compression or torsion are critical like

this box beam right here this box beam

runs beamed a beam here we have another

box beam that runs beam to beam forward

we also have structure underneath the

mast that is made of wood that really

works well with compression 90 core or

any honeycomb will not do well in those

situations so what is involved that

brings me to this piece of wood here

this is the last piece of a pallet of

door blanks that I bought at a Marine

auction a yacht manufacturer bellingham

had a surplus of just different sized

door blanks they were all inch and a

half thick

all night and core construction with a

mahogany skin and solid genuine mahogany

inlay I made an offer on them and got

the entire pallet for ten dollars a slow

so I've been using those honest a basic

I have made all the doors out of these

slabs and this is the last one

I'll show you how he did it all right so

while teals working outside first off

can I tell you how excited I am that he

is working on our final door the fifth

of the four doors that he has completed

I don't really count the cockpit door

just because he built the frame and it

already came completed so yes

it's gorgeous it's beautiful it's safe

but these ones he actually had to build

it from scratch so I'm gonna show you

the four doors that he has completed

while he works on this bit I'm gonna

take you first down to Emma's room so

here's Emma stateroom door and it just

looks like your average slab of door not

anything fancy the amount of work that

teal had to do to get it to this is

amazing actually it's pretty astounding

because it's just a piece of slab nida

core sandwich with mahogany to make it

really strong and teal had to fibreglass

ferret and get it to a smooth finish for

paint we went with the Seattle gray

inter luxe paint just because he wanted

to break up the white you guys know that

we like pristine white on the boat but

just to break it up and give it a little

personality we decided to go with the

grey

I gave Emma these really cute mirror

stickers that she was able to put all

over her door just to give it something

a little Jewish I guess but she loves it

I like it gives it a little character

makes it fun for her it is a kitchen

room now I'm going to show you this door

so this is the guest stateroom door and

one of the things about this door is it

looks normal looks like the other door

but this one gave teal a heck of a

because it is an articulating door he

had to manufacture something so then it

still went all the way down to the

bottom and in in relationship to the

fact that the whole curves he wanted to

be able to have that articulate so then

it still went open and close so I'm

gonna give you just a little thing you

see how that kind of bends it still

works

pretty awesome right now the other thing

that I would like to see happen with

this door is I'd like to get a

full-length mirror on all of them just

so then it just kind of opens up the

space but I don't need it right now just

yet but it'll come okay so that other

one I'm going to show you the head door

which actually is the first door that

teal built and this one's really special

just because this one was really hard

this one was intimidating just because

yeah it looks normal

it looks easy but then it kind of curves

with the ceiling so the cabin curves

down as it gets closer to the side hulls

so we had to figure out how we're gonna

do this we decided to do this swing to

go out and I have my mirror you see how

that opens up people have asked if this

is a toe catch and no it's not believe

it or not it's not just because nobody

walks this close against the wall he

likes it because it hides all his to-do

lists

you guys see our famous to-do list that

keeps growing but I think door is

somewhere here I don't know I know it's

here somewhere

and it seems like every time we get rid

of one more pops up we're just gonna try

to do all the safety and necessities

before we leave all right so the last

one is obviously our master and again

it's a great door we use the same

continuous hinge on all the doors to

give it a perfect reveal nothing torques

or anything on it so that's great we use

the same handles on all of them so then

if there is repairs or replacements we

have extras this one also cut it catches

it's amazing that you can't hear

anything once the doors closed

so this is why I'm so excited for the

last door I think this last door might

be a head scratcher for teal because it

looks normal and it's not like the one

in our guest stateroom that's

articulating because this one kind of

goes away it's not quite wide enough so

he's gonna have to figure something out

so then the door can still open and

close without it being super awkward I'm

excited to see what he comes up with I'm

pretty sure it's gonna be awesome but

until then I'm going to assist and help

him however I can't

okay I have a 20-inch door opening

that's my rough opening this is 21 and

3/4 inches what I need you to find out

is how far does this mahogany how far is

it inlaid into this door and that's

pretty simple

take a couple of readings

inch-and-a-half so now I know that the

in light comes in a total of inch and a

half so I'll lay that out on here

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okay the only reason I made these marks

is just to give me a frame of reference

of where the wood ed is in relation to

where the ninety cord is laying out the

width of the store is pretty simple

actually if I have a 20 inch door

opening that's my rough opening I take

off three eighths of an inch and that

allows for glass it allows for the door

gap and the hinge so in this case I am

21 in 3/4 so that put me at 10 and 7/8

to my center mark

if I have a 20-inch rough opening minus

3/8 that'll be 19 and 5/8 19 and 5/8

divided by 2 will be my half mark okay

now here's my new line this will be my

door slab you see that I have still bump

5/16 3/8 of an inch right here of

mahogany and that's what I was shooting

for and that's why I laid this out

I need this little strip here so when I

lay my glass over I I could router a

nice radius on it I could attach my

continuous hinge to it I could inlay my

new door hardware to it it gives me a

screw holding all through this area here

and that'll carry around to three sides

the fourth side when I cut it to hide

I'll have to inlay but that's coming up

I'm gonna make this riff before I

measure this out making the trip first

I'll be able to rip it sand it and get

it true and they'll be able to pull my

19 and 5/8 off that and get a much more

accurate number

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that is a tough rep six feet through

genuine mahogany with my trusty little

battery-powered saw it's done this cut a

hundred times and it keeps powering

through

now I'm gonna got the first rip off I

could pull an accurate measurement to

get a nice width nineteen in five days

it's amazing I'm only leaving about

three-eighths of an inch of mahogany

near this stuff is the majority of the

weight in this panel here actually I got

a piece record here's another piece I've

cut out so the 94 I mean this piece

right here weighs six ounces it's great

light so once I get the bolt of this

perimeter cut off this door slab will

weigh quite a bit less and that's what

I'm going for

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cutting this mahogany in the cockpit is

thrown a lot of dust down on the ground

but luckily I have quite the dust

control system

I love my dust collection system you're

very lucky that you're talented and

peace otherwise I wouldn't do this all

the time

okay before I start shaping this door

slab I need to look at how the door

needs to swing I can't swing it into the

stairs and I can't swing it this way

because it'll it'll hit the steps on the

way by and still will still be a issue

with the staircase here so my choices

are swinging it in if I swing it this

way let's go to back here it's not a big

deal but it covers up the sink and part

of the head so that forces you to close

the door if you ever want to use kind of

walking into the room just to use the

sink

you'd have to close the door some way

other option is swing it this way it

misses the port light so that's on issue

but the issue is down here the whole

shape I cannot physically swing the

store into a curved hole to do that I'd

have to articulate the door like I did

in the guest stateroom not a big issue

just about twice the work

okay now that I've decided I'm gonna

build this articulated door rather than

a conventional door

I'm gonna build the upper half first

it's 63 and a half inches tall and I

want to get the hardware and everything

installed on there and get this door

glassed and finished and installed that

way I could get hard measurements for

the lower articulating portion so 63 and

a half is my first guy

I need to fill in this old mortise for

the old handset next so I'll just square

it off

and a poxy and a nice spacer

can't see how this fits that's nice and

snug okay back it out pack it with some

epoxy and get it put in place

a little epoxy in here doesn't need much

because I am overlaying this entire slab

with cloth and epoxy this will just keep

it from wavelength

guarantee it'll never move but let's see

how it goes okay

here's that smirk of embarrassment

about one minute after I cut my slab

down I went down to test fit it and

realized that I can't do an articulated

door on this particular rough opening

and I'll show you why in a minute

so I'm now putting this door back

together and we'll just have a standard

swinging door swinging into the sink

darn it okay you're probably wondering

why I cut the door in half and then

repaired it back and here's my

explanation I was torn whether or not to

swing the door into the hole which I'd

have to have an articulated door and

have a cut or swing it into the counter

and then I have a full slap I kind of

kicked around both ways and I could have

gone either way but I went this way by

mistake so I repaired it mice mistake

happened five years ago when I was

building this wall here this is

perfectly plumb and true this is

perfectly plumb and true to right here

there is a hump you can't see it and

I've never noticed it and I'll show you

how this happened but by having this

hump here my choices are either cut this

structure out and rebuild it reclass it

ferret painted and I can do that

and I made you that the future but it'd

take a week or so or I could just swing

the door on this side which I can have

the door in in a couple days so that's

how I decided to do just put the door

back easy fix

put a spline in the door epoxy back

together and I have a solid slab again

let me show you what I did

how this happened if you take a look

here is that opening when I frame this

up I ran a stud here six inch on center

up through this wall with foam in the

core I ran a stud here I ran a header

and studs six inch on center across here

I didn't want to run a stud here because

it was creating this 95 degree slant

right here so what I ended up doing was

running studs this way into the hole and

I was able to fill that with foam these

are six inch on center everything was

perfect until this last uh drinker some

reason it bowed out 3/16 of an inch

doesn't seem like a lot but it's enough

that if I put a continuous hinge on here

it won't work and it's not like I could

just plane that off this is wrapped with

glass there's actually stainless steel

fasteners holding that stud in so it's

it's not major but I can I can tear it

out and redo it but I'll just go to plan

B and swing it into the counter

now that I've cut the majority of the

mahogany out going to the left is just

the skin a thin layer around and the

ninety four things actually getting

pretty light that's what I want next

thing to do is this knock these radiuses

into the corners these are going to be a

little bit proud I just want to get it

close so I could shape it and scribe it

once I get it set and mounted

okay the next thing I need to do is the

slab needs this corner knocked off as it

comes through here this is the hand side

this is the handset side so I'm going to

elevate this about 3/8 off the floor and

then hold it about 3/8 off this wall to

right here and then the slab starts so

I'll calculate that next here's a little

trick I like to do I took all the

calculations as hard measurements to

calculate this knock on the corner here

then I went down and made a template out

of cardboard then my double-check

he's lining these up now I feel safe to

cut it okay it's the next morning my

urge is to get right outside and start

working on my project this door slabs

calling my name and I want to get it

hung today but first things first we got

to get Lynn off to work

get her ready get her out the door then

I got to take care of Emma she demands a

hearty breakfast that girl can eat she

could eat easily more than I did so make

her a nice hearty breakfast and get her

squared away best time to take care of a

couple chores do the dishes make the

beds and laundry anything else that

needs to be done around the boat we try

to get all this done by 8:30 every

morning because at 8:30

that's when Emma starts her home school

and we homeschool

hang on for it

we homeschool every morning from 8:30 to

about 12:30 and during that time I am

doing my work at the same time so I'll

be bouncing back and forth

I do work from the boat and that's my

time to get my work done bounce over

help out my bounce over do my work and

we try to get it done in four or five

hours every day after that it's off to

violin practice so we head out go across

town and take Emma to her violin

practice and that's important she loves

it she's just taking a liking to it so

we're just gonna keep pushing it to do

it after violin we get back to the boat

now it's 1:15 so we have a quick lunch

and I get to work so I get to work on

the boat from about two o'clock to about

4:30 5 o'clock every day the rest of

time is editing and taking care of life

so I'm anxious to get this book done and

it just calls me to get it done but boy

I got a hustle okay now I could get to

work so my goal today now that I've got

my slab roughed out I need to cut

my continuous hinge get it installed

here's my handset that I'll be

installing but first I want to get the

the hinge mounted get this installed in

the rough opening and and why I'm doing

that is because I've cut this thing a

little proud all the way around I want

to get it hung that way I could describe

my reveal and get a nice even reveal so

that's the next step so here's how I do

that okay the easiest and cleanest way I

have found to make a nice cut on the

stainless continuous hinge is just using

my Dremel with a heavy-duty cut-off

wheel

you may go to one or two but you'll get

a nice clean cut

okay let's see how this turned out nice

and clean your report card is a fold to

hinge closed and see if the points match

up and I'm happy with that tells you if

you got it square or not I'm just

putting a few of the screws in to hold

the continuous hand just in case I need

to do any adjustments and there we go

okay now to go test in this

okay go in I just need your home for one

minute okay we know what I'm gonna do

put the bottom in you can yeah okay now

push it into place it's gonna be tight

push the top a little bit more a little

bit more now I'm going to scribe it that

looks good

okay now that I have this scribed I'll

shape this end and I may do this two or

three times before I get it perfect but

each time I get closer and closer so I'm

happy

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okay got it shaped and I put a couple

little tacks in just to hold this

continuous hinge let's see how this

thing looks now reveals are getting

pretty nice but I'm running out of time

today this video is get all along so

what I'm going to do is cut it off right

here next week

I'll finish routing the edges filling

the 90 core putting my handset in and

then glass cloth and hopefully Prime and

paint we'll see you then

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