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Jun 16, 2023

Duracell Project: Finishing the boat shower, without wasting

To build the bathroom on his Duracell sailboat, Matt uses flat panels, which he cuts with templates. These fiberglass-foam sandwich panels are vacuum-laminated. But each application requires materials

To build the bathroom on his Duracell sailboat, Matt uses flat panels, which he cuts with templates. These fiberglass-foam sandwich panels are vacuum-laminated. But each application requires materials that are often disposable. Based on his experience, Matt now laminates several foam sheets at a time. This saves on tear-off fabrics, as two sheets on top of each other only need three, compared to four, one on each side, if they were laminated separately. It also saves time.

After positioning the side panels of the shower enclosure, Matt fills holes in the shell with filled resin, then laminates the inside of the repair. Then it's time to drain the shower. A panel with a drain grate is positioned at the lowest point of the floor, which will send the water to a buffer tank and a pump to drain the water. For a good seal and flush positioning of the grate, Matt drills through the composite panel to the diameter of the pipe. Using a template, he then cuts only the top skin and foam to the diameter of the grate. This way, the grid will not fall off and can be glued in place. Finally, for a good drainage, Matt installs small side elements with the right slope.

In the second episode of the week, Matt fixes the last partitions. While the epoxy glue dries, they are held in place with screws. Then it's time for the finishing touches, rounding off the corners with filled epoxy and glass cloth strips.

To finish his week, Matt dismantles the last chainplates of the boat, always with some difficulties, levering with all he can.