Building New Dorades (Updated 4 Apr—Project Complete

[John Stone]

The dorade box: I used my Bosch jig saw to cut along the line I scribed on the box sides yesterday. I smoothed the freshly cut edge with a spoke-shave. Then I used a trim router with a 1/2” round over bit that had a integral guide bearing to radius the edge. The radius on the edge will match the concave corner molded into the molded riser on the cabin top. I made two passes with the first pass shallow. On the second pass I set the bit deeper than usual leaving a 3/16” edge. The edge is easier to file for final shaping to ensure the best possible fit on the boat.

The dorade lid: I used a 4 1/4” hole saw to make the cut out for the bronze cowl vent base. The key to avoid tear-out when using a hole saw is to either clamp a piece of wood to the opposite side or have the center drill bit penetrates the other side but before the saw cuts through, flip the wood over using the center drill hole as a guide.

With the hole cut I used couple cabinet rasps to enlarge the hole slightly and round over the edge so the base easily fit flat with a bit of wiggle room. The wiggle room is important to provide a way for the bedding compound to flow down into the hole around the base.

[John Stone]

I test fitted the dorade box yesterday. Minor tweaks required for final fit. All that was required was a few strokes with cabinetmaker’s rasp on the underside of one corner. Rain today. With luck, they will be installed Saturday.

[Chrisa006]

Beautiful work John!! Thanks for sharing.

[John Stone]

With a couple of days of improved weather at hand I tapped off the deck and the box. I installed the teak dorades with mahogany colored Sikaflex 291 Slow Cure bedding compound. Then, I plugged the fastener holes with teak plugs. Finally, after trimming the plugs flush, I installed the bronzed base PVC cowls. Project complete.

[Jim Walsh]

Nice work, John. A handsome addition to a beautiful vessel.

[John Stone]

Thanks Jim. The poor Far Reach is absolutely filthy. The dock water has been turned off since late Nov. they are about to turn the water back on so she will get a much needed bath to remove dirt, pollen, grime, Jet fuel residue, and some mildew on the north side.