Living For Sail · video

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To restore the cockpit sole of a Liberty 458, the owner replaces the center core with 1-inch Kusa panels, securing them with epoxy and vacuum bagging to ensure a flat, void-free bond. To mount the binnacle, he designs and 3D-prints a custom vacuum-powered drill jig using a Prusa Core 1 printer and PLA filament. The jig features a vacuum port and 1/16-inch neoprene tape to create a seal, allowing the jig to hold firmly to the fiberglass surface under 25 inches of mercury. This setup enables precise drilling of the main binnacle hole and four mounting bolt holes. He further uses a 3D-printed guide to hold a 3/4-inch router bit, cleaning the hole bottoms to accept G10 backing plates. These G10 plates provide a hard mounting surface beneath the future Permateek decking, preventing compression of the synthetic teak under the binnacle's load. 3D-printed vacuum jigs provide a repeatable, accurate method for drilling and routing hardware mounting points on complex boat surfaces.

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