Complete rebuild of the bulkhead of a 1988 37’ by Don & Connie Theroux out of Cranston, RI

Seaview a 1988 37’ mid galley

Amazing what formica will hide

Water damage

Side walls completely rotted under formica

Everything had to be removed to get the wall out

Sill also rotted under teak

Interior and exterior wall was same piece of ½" plywood

Goal was to save exterior fiberglass skin and re-laminate a new wall

Sample of the water damage

Routed the entire wall from 1 1/8" to ¼". Sections had to be taken right down to the skin. Bottom 6" to 14" of the wall had to be skined of the old wood as well as the starboard side of the large bulkhead window

Re-laminated bottom of wall with 1" clear fir. Overlapped 3" on remaining plywood. Built up area around window with alternate layers of 3/16" x 4" clear fir to 1" thick.

Covered entire wall with 3/16" x 4" clear fir-2 layers

Completely epoxied and ready for sanding and the application of veneer

Wall went back in easily. Bridge deck did not sag. Wall was out for 3 months.

Original teak trim saved and replaced

Better than new!! What a job well done…

The maestro….

Side ‘wings’ replaced with plywood and original formica

Fiberglassed sills and side corners

Teak will cover this

New teak threshold

Deck Lockers were also rotted

Bad sections were routed out and replaced with the same fir used on the bulkhead.

New headliner too!

See them in Montauk!!