The completed project

Looks good right?  Looks aren't everything.  Water has visited the wood around the companion way ladder and engine compartment.  There's some rot, now it needs to be addressed.

I hauled all the parts off the boat that could be removed and brought it to my buddy Mr. Fix-It's house.  He's an old friend I served with in the Navy.  We're both retired now, and he's my wood working connection.  He's got the skills and the tools to handle any of the projects that I can't handle with the assortment of hand tools that I keep onboard.  He constructed my Shadow Box when I retired.  He also refinished and modified my sword case for installation on the boat.

If you look at the picture of the original installation; the only indication of a problem is a little de-lamination at the bottom of the steps.  A little disassembly later, and you can see the extent of the problem.

A sheet of plywood, a few cuts on the table saw, and the re-assembly begins.  I reassembled the stairs using the original steps, insulation and hardware.  I also added a fire port.  On the bottom edge I put some nylon floor savers like you find on the legs of stools and chairs, so if there were to be some water to come through the area, the wood should be elevated enough to stay out of it's way or at least be able to dry out more quickly.  I also put some decorative brass on the new plywood to protect the corners and prevent delaminating.

I also installed a fire port so, if I were to ever have a fire in the engine compartment, I no longer have to open the whole compartment to address it.  I simply open the fire port insert the hose from the fire extinguisher bottle and flood the compartment with Halon U.S. Navy engineering space style.

The vast majority of the water damage was caused by a previous owner who had mounted an air conditioner in the companionway without leveling it.  The water in the condensation tray dripped inside the boat rather than outside into the cockpit.  I know this because the A.C. came with the boat and I ran it myself once, just to see if it worked, and ended up with puddles in the same places I found the rot.

Of course the rot isn't limited to the removable parts, that would be too easy.  The wood around the edges of the engine compartment is also soft.  Fortunately, the damage is limited to a couple of small areas that are not visible when the stairs and engine compartment is assembled. 

To repair this, I got a wood restoring epoxy from West Marine.  After drilling some 1/8" holes in the affected area I injected Git Rot Penetrating Epoxy into the holes, the capillary effect draws the epoxy into the wood.  Once dry it's firm and solid.  A little wood filler & sanding, and it's good as new... just not as pretty.   So, install some aluminum angle iron and plating to cover the defects, paint it to match the wood work, and hopefully prevent this problem from re-occurring.

The Cost:

Plywood: $50.00

Stain:  $8.00

Aluminum: $30.00

Brass corner plates/nylon floor protectors: $12.00

Grand Total: 

$100.00 and a day of labor

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