A new window in an aft cover, classic 68’ motor cruiser

The varnished wood motor cruiser in its boathouse with the aft deck cover in place.
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The customer’s story

The owners of a classic wood-framed, wood-planked motor cruiser, kept in Bristol condition, wanted more light and a view aft from under the after-deck cover: a clear window between the deck roof line and the top of the transom, for comfort at the dock or at anchor whenever the cover is up. The cover itself had age caused wear and tear. They wanted it kept in service until a new one is made, and then kept as a heavy-weather back up cover.

The scope

A vinyl window set into the existing aft deck cover, reinforcement patches over its worn and torn areas, and new custom shock cords and stainless lashing hooks to tension the cover along the transom.

The approach

We cut a new window opening in the existing panel and framed it in new Top Gun fabric to reinforce the existing Sunbrella cover fabric, patterned flat on the bench so the frames sit square on the boat. The window is six feet by four feet of O’Sea 40 mil clear vinyl, coated against UV, scratches and stains, so they stay clear through Pacific Northwest seasons. The worn and torn areas were reinforced with patches of Sunbrella Shade in Toast, close to the cover’s own color. Along the rail, the new 316 stainless steel lashing hooks were installed to hold and tension the cover, new fittings were bedded so water stays out of the varnished wood, and custom shock cords were cut to length with marine grade heat-shrink ferrules to prevent the ends from fraying. All seams on the cover were fully restitched as the cover’s original polyester stitching had reached end of functionality due to weathering.

The result

Light on the after deck and a clear view aft under the cover, a cover that will serve until its replacement and then as the heavy-weather backup, and fittings that will not stain or rot the brightwork. Workmanship and hardware carry our two-year warranty.

Materials

  • Clear WindowO’Sea clear vinyl, 40 mil · UV-, scratch- and stain-resistant coatings
  • FabricSunbrella Shade, Toast 4628-0000 · reinforcement patches over worn and torn areas
  • Thread138 heavy weight tan polyester UV resistant thread
  • Lashing hooks316 stainless steelBedded along the lower teak rail
  • Shock cordmarine grade polyester cover shock cordTensions the lower cover to the rail
  • Marine sailmakers leatherSplit pearl · grayChafe protection
  • FabricTop Gun toast color
  • Shrink wrapMarine grade black with heat activated glue liner
  • #2 GrommetDot brand nickel plated brass
  • Patterning paperTyvek
  • ZipperYKK #10To add a future lower transom panel

Photographs

Each photograph opens larger.

The varnished wood motor cruiser in its boathouse with the aft deck cover in place.
The aft cover and new window in service under the boathouse roof.
The new clear vinyl window in the aft deck cover, seen from inside, with a passenger ferry passing astern.
More light and a new view aft, with the cover up.
The aft deck under the cover, a teak table and chairs, light coming through the new window.
The aft deck seen in a new light.
A vinyl windowframed in canvas in preparation for sewing into the cover and laid flat on the bench.
The window framed in canvas in preparation for sewing into the cover.
The modified cover with protective paper covering the new vinyl window, on the cutting table.
The modified cover with protective paper covering the new window.
The aft deck cover laid out on the loft's cutting table.
The cover on the loft table being prepared for delivery to the customer.
New leather reinforcement and chafe protection for the mooring lines, with snaps along its edge.
New leather and Top Gun mooring lines chafe protection.
A corner of the cover with bound edges, a hook-and-loop strip and snaps.
A bound corner with new leathers and new hook-and-loop strip.
Shock cord loops from the cover's lower edge to the stainless rail on the varnished transom.
Custom new shock cords to the transom’s teak rail tensions the lower edge.
The cover's zippered edge with shock cord loops over the rail.
The cover’s lower edge with new zippers and shock cord.
Shock cord passing through a 316 stainless steel lashing hook on the teak rail.
Where the cord meets the rail. A new 316 stainless steel lashing hook.
Blue tape masking the varnished wood beside the rail where a fitting is to be mounted.
Masked before bedding, so the varnish stays clean.
A new 316 stainless steel lashing hook held in place on the masked teak rail.
The new 316 stainless steel lashing hook placed for a dry fit check.
A new 316 stainless steel lashing hook bedded with Life Caulk.
A new 316 stainless steel lashing hook bedded with Life Caulk.
Close-up of the new stainless hook plate bedded in sealant on the masked rail.
Bedded, so water stays out of the wood.
A new stainless hook plate mounted on the rail, shock cord above it.
Mounted and cleaned. Blue tap comes off next.

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