Router Question

[craig shire]

I need to cut a new bottom panel for my old layout boat.
The bottom is basically a large oval made from 4 separate pieces.

My initial plan was to remove the bottom and use the pieces as patterns to trace the shape on to the new plywood for the bottom.

Now that I am in to it the bottom panel is in worse shape than i anticipated and I am not sure I can remove it without destroying it and making it unusable as a pattern.

Would it be possible to use a flush bit in a router to cut the new pieces using the existing panel edges as guide? Would tear outs be a problem?

My other option would be to make paper or cardboard patterns and use them to transfer the shape to the new
plywood and cutout with a circular saw.

 

[Ed Auman]

Can you rip out old floor install new floor. Cut with jig saw 1/4 to 1/2 inch large all the way around. Then router it with flush bit? Ed

 

[Ray]

Hard to really see what you are working on with that small of an image.

Use contractor kraft paper to make patterns as you take it a part is one option.

The flush trimming bits will not create much tearout in plywood that can't be easily fixed with epoxy.

If the bottom of the coffin area has verticle sides jig saw the new wood to near the size than then screw it down and flush trim it to fit. It will be flush to the outside of the sides of the coffin. The coffin sides are another issue. The rest of the bottom should be able to be cut the same way with a jig saw and then flush trimmed.

 

[craig shire]

Sorry for the cell phone photo. The girlfriend has the good camera hidden someplace and she wasn't home until late last night.

The coffin sides are flared and both the sides, ends and bottom are in bad shape and will need to be replaced.

I did get the coffin removed from the flat bottom portion last night. The hole is ragged due to disintegrated plywood, but I now have a flat surface to use for pulling patterns. I wil just trace the patterns from the old bottom to new plywood and cut out with a circular saw.

The top of the boat is in fine shape. I've stripped all the old paint and gluvit and it is ready for paint when the new bottom is back on.

The divers are down and I need to get this thing done! I'll post some better photos when all is done.