Installing wood boxes in a boat

[Kevin Puls]

I am not sure where to start, so I figured I would start here.

I will be taking delivery of a boat in the next few weeks that will be dedicated mostly to hunting.

Along the insides of the floor/cockpit area I want to build storage boxes the length of the cockpit, approximately 105". It is an aluminum jon boat.

What material that is available to the common person that would be the best compromise of weight and durability?

How do I seal it or coat it to make it last as long as possible?

To give a notion of my initial thought, I was thinking half inch exterior plywood with lots of spar varnish and some exterior house paint.

 

[Gerald N]

You will have a compromise with all materials.

If you want light weight and rot resistant go with PVC trim boards or FRP. Both are expensive and not as impact resistant as metal or plywood. PVC trim will be tough to make waterproof if multiple pieces are needed to span width. PVC trim is $$$. FRP comes in 4X8 sheets at local big box home improvement store. Both of these materials should not be weight bearing.

I used PVC in several marine applications and it is great but limited materials were needed. I would not suggest using this stuff for large projects due to cost.

Plywood seems to be the go to product.

 

[Steve Sanford]

Kevin~

A conceptual sketch with nominal dimensions would be helpful. Since I'm basically a wood guy, I would first look at 1/4" AC plywood with a light frame of a stronger lumber - Philippine Mahogany, Douglasfir, White Oak, etc. I would cover it (outside and bottom) with 4-oz 'glass set in marine epoxy. For the top/seat, I would use real lumber - maybe Cypress with cleats underneath every 16 inches or so as stiffeners. Duckboat paint on all surfaces - but a pale grey semi-gloss enamel inside so you can see what's in there (and maybe a string of red LEDs, too). Also good to put sleepers on the bottom to keep them off the hull itself.

The storage bench/seat for the pilothouse of the Cassiopeia was built this way. It has a shelf along its back wall to hold small stuff like shell boxes, lights, thermoses, gloves, etc: http://www.duckboats.net/cgi-bin/forum/gforum.cgi?post=255752;search_string=cassiopeia;#255752 (pretty late in the post)

Details like hinges and weatherstripping will be important in the design to keep everything truly weather-proof.

Will these be permanently fastened or removable?

Will they live outside year-round or just while gunning?

As always, I look forward to your progress.

SJS

 

[Mike Trudel]

Steve, can you post a pic of the storage bench/seat open, so we can see the underside of the top?

I too am converting the two stern bench/seats on each side of the motor from open concept, to a sealed storage seat/bench setup. Thanks

 

[Steve Sanford]

Mike~

I just searched my files and I do not have a photo of the box open - and it's now 250 miles away. I did not put cleats on the underside of this top because it was 7/8" Mahogany, it will live inside the pilothouse and the hinge is in about 4 inches from its rear wall - so that it will stand open with the lid against the coaming.

If this were a box as Kevin plans, I would probably cover the piano hinge with a strip of rubber/vinyl/canvas to keep water out. I joined the Mahogany boards with biscuits, Titebond III and plenty of bar clamps.

Note the rounded corners - on both the box and the lid - to avoid shin-bangers and to protect the 'glass skin.

Because of height limitations, I removed the two 1 1/2" high cleats on the bottom. This used to be my toolbox in my old Ford Ranger - and replaced them with discs cut out of shop mat.

Hope this helps,

SJS