Sailing Magic Carpet · video

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The refit of a Cape George Cutter 36 involves a complete reconstruction of the cockpit to address previous rot and improve storage capacity.5:08 The project requires moving the aft bulkhead forward to enlarge the cockpit lockers and installing new longitudinal framing to support two custom hatches.5:22 To ensure structural integrity and waterproofing, all new plywood surfaces are glassed with woven cloth and epoxy.6:50 The process includes fairing surfaces with TotalBoat compound, priming, and sanding to achieve a smooth finish.6:42 To mount a gear shifter through the cockpit plywood, the builder uses a router to recess the panel and creates a fiberglass flange to seal the penetration.9:51 The builder also sources custom-made gutters and hatches from Wells Fiberglass, utilizing their CNC-machined molds to ensure precision and save time.22:54 The cockpit deck is reinstalled using carriage bolts after the underside is sanded and painted.16:54

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