Saturday, June 23, 2007

Deck Cap Plan

Last night I got my inspiration for the deck cap design.
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It will be patterned after the breasthook of the yacht tender, which was formed with two pieces of Meranti Mahogany, and a strip of red oak epoxied in the middle. There is a crown on the oak strip that was formed by planing and belt sanding the breasthook. Then fine sanding, a couple or three coats of epoxy and at least five coats of marine varnish.
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1x8 meranti boards will be positioned over the rail curves from post to post, then curves of mahogany will be jigsawed from one side and jointed to the other. All of the angle joints will be expoxy glued and reinforced with biscuits.
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Under all of the edges will be a 3/4 strip of oak, which will form a two toned illusion of a 1 1/2" rail piece.
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I'll set my router edge guard for 7 1/2" inches and run a straight edge bit along the entire rail to insure that the rail curves are parallel.
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Then I'll reset the edge guard to center on 3 1/4" and make the center plough cut which will house the middle oak strip. Then 1/4" oak strips will be cut from a 14 foot oak board that I have been storing for a couple of years. The thin width of the oak should allow it to bend easily into the plough cut, which will be bedded with epoxy.
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When all that dries, I will plan and sand the crown and edges.
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The contrast of the dark Mahogany, enhanced by the oak highlights, with the painted white curved rails should be cool as hell!!!
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I'll definitely take pictures to show you. If all goes according to plan, we should see this masterpiece before the 4th of July when Mike comes home again.

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