Hi Jonathan I just completed this project in the Spring of 2016. The Frers 33 is not the same boat as the C&C 35-III but a lot of the techniques for this job are similar so I will answer a bit of what I can to some of your questions.
First be prepared for sticker shock. I purchased a single 4x8 sheet of 3/4 inch teak and holly and it was over $600 CAD. 1a) Lining up. I took out all of the existing pieces and took them home. When I traced out and before cutting the new pieces I lined up the holly lines with those of the pieces being replaced with the assumption that it would line up the same as the old sole. It did. I think the first step will be to ensure your current sole does in fact have the strips lined up. 1b) Number of pieces. Try an inexpensive piece of 4x8 pressboard or paneling or something similar that is 1/4 inch thick. When I bought my sheet of teak and Holly it came with something like this to protect the surface during transport. Once you have this lay out the pieces of old sole on top and trace them out. You can then turn it over to trace out the remaining pieces on the back. Is kind of like a jigsaw puzzle but will give you a pretty clear picture how many pieces of sole material are needed. If you use a couple of these 1/4 4 x 8 sheets you could also cut out the traced pieces and use them to test fit in your boat as I did before cutting the expensive teak and holly. One thing I encountered was that my jigsaw fitting had to be amended a bit when I laid the old sole pieces atop the new sole to account for the lining up of holly strips. 2) Tools. I am certain that others have better suggestions for tool but I used a circular saw for my straight cuts and a jigsaw for the curved cuts (there were not many curves). On the tapered edges along the underside I used a angle grinder with a sanding pad. Also a Random Orbital sander to smooth the edges of my cuts. I put masking tape over the lines to be cut before using the saw to reduce splintering. 3) Epoxy. Yes the underside but more importantly the edges. Almost every case I have heard of soles delaminating and the finish lifting starts with water intrusion from the edges. Yes the first coat should be thinned (West has advice about how to thin for first coat on wood). At least three coats IMO. 4) For the exposed cosmetic surface I applied three coats of West 105/206 followed by three coats (or four?) of Epifanes varnish. I chose the Satin finish and in a test piece it looked far better than the gloss and hides many small imperfections. I used a brush for varnish and roll/tip with foam roller for epoxy.. Interestingly this year I learned that diesel fuel is preferred for maintaining a varnish brush when not in use. (I used a new brush every coat on the sole) A few other brief comments. i. My fall project list now includes pulling up the sole to sand and reapply epoxy to the edges. I plan to do this every second Fall. I am paranoid about water intrusion ii. The largest sections will barely squeeze in through companionway. Expect to have the trim around companionway marred and in need of refinish. iii. getting the large sections up a ladder and into a covered boat in the off season is very tricky. Plan ahead Best of luck with this project. The end result will be outstanding! Mike Persistence 1987 Frers 33 #16 (not a C&C) Halifax, NS http://users.eastlink.ca/~mhoyt -----Original Message----- From: CnC-List [mailto:cnc-list-boun...@cnc-list.com] On Behalf Of Indigo via CnC-List Sent: Wednesday, September 27, 2017 12:33 PM To: cnc-list@cnc-list.com Cc: Indigo Subject: Stus-List Replacing Cabin Sole - 35MkIII I am just about to start on the project to replace the teak and Holly cabin sole on Indigo. I have gleaned much info / advice from past postings on this list, but was wondering if anyone has prepared a "step by step" guide. Things I need help on! 1) steps to ensure that the Holly lines up exactly for each piece. I recently asked, and was told I need 2 pieces of 4' x 8' to complete the job and allow the lines to match up - but I thought from past postings that 3 pieces are needed. Can someone who has done a 35mkiii confirm which? 2) best tool(s) to use to cut out the new pieces using the old boards as templates. Any tips / techniques to ensure accuracy and minimise damage to new veneer? 3) I know I should epoxy the underneath (and sides?) of the boards - how many coats are advised - can the first coat be "thin" to aid penetration into the plywood? 4) advice on what to use for the top surface - presumably a polyurethane varnish - preferred brand, number of coats recommended, what finish (matt, semi-gloss, gloss?) -- Jonathan Indigo C&C 35III SOUTHPORT CT _______________________________________________ This list is supported by the generous donations of our members. 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