Suggestions on rebuilding bow cushion

[pinellas50]

1993 Starcraft fiberglass bow rider.

I am in the process of rebuilding the port side cushion. The plywood on the original rotted out but the vinyl is in great shape. My intentions are to redo the backing and put the original vinyl onto the new back board. The back board or base for the cushion must contour with the hull.

I first tried the steam and wet rags method to warp the new plywood to shape. That didn't work well so I gave up on that. The approach I am using now, which looks like it will work, is cutting grooves in the back of the plywood a couple of inches apart. This is allowing the wood to flex like it needs to. Now the question.

I intend to seal this wood with epoxy resin I bought at West Marine. I first want to fill in the grooves I cut, which are now expanded from bending, and then seal it. But this is going to seal the wood in a rigid shape. So I have to find a way to make the wood keep it's current shape when I unbolt it from the hull. How do I do this?

My thoughts are to apply resin to the front of the board(the one that will be covered by the vinyl) and the sides. I'm hoping this wil harden to the point that it will retain the woods shape so I can address that back of the board when I unscrew it again from the boat.

Any thoughts?

My thoughts are

 

[pinellas50]

Re: Suggestions on rebuilding bow cushion

Also, the way my boat is set up it is impossible to access the other side of the hull from where the cushion bolts on. So I must use screws to hold it to the hull.

I doubt that changes anything but I'm just throwing it out there.

 

[109jb]

Re: Suggestions on rebuilding bow cushion

I used 2 pieces of 1/4" plywood laminated together and held in the curved shape until the glue set. Here is a link.

http://forums.iboats.com/showthread.php?t=347724

 

[pinellas50]

Re: Suggestions on rebuilding bow cushion

This step specifically is what I am talking about. How do I get the wood to keep it's shape when I unbolt it from the boat?

It looks like you warped your piece. I had to cut quite a few grooves on the back side of my wood to get it to bend enough. But the wood will go back to its flat, normal stance when I unbolt it again. I need it to retain its shape because I want to seal the entire piece with epoxy resin which will harden and render the wood unbendable when it dries.

 

[tschmidty]

Re: Suggestions on rebuilding bow cushion

Hmm, not sure how you would do it with the notch method. If you use 1/4 and glue, you can screw the two pieces to the hull while it sets and it will hold it's shape.

Epoxy retains some flexibility so I don't think you need to worry too much about it cracking, but your milemage may vary.

In your other thread you mentioned how to attach it. Screw it from the fron in between the sections of foam, pull it out of the way and screw it and the screws will be covered when you put it back.

 

[pinellas50]

Re: Suggestions on rebuilding bow cushion

I've come to the conclusion that I am over thinking this. The major dilemna here was the ability to fill in the grooves I cut while having the wood retain the correct contor. Well this wood is bolted to a hard surface so I really don't see a need to fill in these cuts. My plan is:

1. Seal the front side(the part covered by the vinyl) and the sides of the wood while it is bolted in the boat.

2. Once dry I will remove the wood and seal the back, except for the grooves.

3. Once dry I will then fill the grooves with sealer and bolt the wood back onto the boat while the final step dries.

4. After all the sealer has dried I will remove the wood once again, put on all the upholstery, and bolt it back on as a final done deal.

The entire hull area minus the screw holes will be covered in painters tape and plastic at the bottom so none of the resin sticks to the hull and possibly adheres the cushion to the hull.

Unless I hear a compeling argument not to do it this way......................

 

[109jb]

Re: Suggestions on rebuilding bow cushion

This step specifically is what I am talking about. How do I get the wood to keep it's shape when I unbolt it from the boat?

It looks like you warped your piece. I had to cut quite a few grooves on the back side of my wood to get it to bend enough. But the wood will go back to its flat, normal stance when I unbolt it again. I need it to retain its shape because I want to seal the entire piece with epoxy resin which will harden and render the wood unbendable when it dries.

That piece is a laminated piece. 2 pieces glued together and clamped in place until the glue dries.

 

[pinellas50]

Re: Suggestions on rebuilding bow cushion

To follow up.............

I got the cushion done and it looks great. Well, it looks almost exactly the way it did before I started the project minus half of the cushion pulling away from the hull.

The relief strip cuts worked great on the wood. I sealed the wood completely with epoxy resin before putting the cushion back together. The wood was still pliable enough to bend into shape after being sealed. I used 3M spray adhesive to stick the foam to the wood and then used monel staples to reatach the old vinyl to the new wood backing.

I took a pic of the wood with the relief cuts which I will post once I download my camera again.

All in all it was kind of a long process to rebuild. Mainly because of the sealing process. But it was very doable for anyone with average to low handiness. I had never done anything like this before and was able to get it done.

 

[pinellas50]

Re: Suggestions on rebuilding bow cushion

I finally downloaded my camera. Here are the cuts I was talking about.

I completely sealed the front, back, and sides of the wood with the epoxy resin before putting the foam and vinyl back on.