Building the Side Window Reveal - 02/11/05Over the years I have verbally explained to several Bertram 31 owners the way that I create a reveal for the fixed glass side windows like seen on Kevin Schuller's 1961 B31 FBC, "Iasgair".
Last evening I hit a stopping point on a project, but decided to do a quick demo series of images that graphically the process.
First, the verbal description:
This process will eliminate altogether the aluminum side window frames and sliding glass. By building a reveal around the vacant window opening, a fixed pane of glass can be glazed in from the inside of the boat, as shown in the following diagram.
Next, you'll need to cut enough core stock both windows. Alternatively, you could buy this stock already cut from a home improvement center. I used wood for this demo, but PVC stock would perhaps be better because of it's greater flexibility.
Once you have the Starboard mold screwed down, two layers of biaxle fiberglass cloth are laid down on both the vertical and horizontal exterior planes.
While the fiberglass is still wet, the core is screwed into place. #6 screws, spaced about 12" will be more than sufficient. Be careful not to screw into the Starboard! After the resin cures, grind back the excess fiberglass flush with the top surface of the Starboard and slightly below flush with the vertical surface of the window opening.
Next, build up the angle surface with multiple layers of fiberglass. I used 8 layers of 1208 biaxle cloth for this demo.
Once that layup has cured, again grind flush the top and front surfaces. This will leave you with a small 45° angle.
At this point, remove the Starboard and further grind down the horizontal surface by about 1/16". Carefully sand the small 45° into a nice full radius. Replace the Starboard. (Hint: A couple of more layers of fiberglass would have yeilded enough material to create a smaller radius...)
With the Starboard back in place, lay up one layer of 1 1/2 oz. mat, butting the horizontal edge to the Starboard, over the reveal, and lapping onto the vertical plane by an inch or so. Add a second layer of the mat, overlapping onto the Starboard and lapping past the first layer on the vertical.
The Starboard mold can now be removed and retired. Trim the overlap flush with the inside face of the reveal, sand and fair the surfaces, and your reveal is ready for paint or gelcoat...
Here's a cleaned up shot of the cross section of the reveal.
We'll be doing this type of window treatment on Gerry Santiago's B31, so hopefully, I'll get some shots of the actual process taking place...
Have fun! Feel free to download and print this article, but please don't use it on a website without linking it to Bertram31.com.
Capt Patrick McCrary
3640 Investment Ln. #15, West Palm Beach FL 33404
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