After the engine well for the original outboard was cut out, a jig was made to fit the new inboard engine.
The box shape structure is the area requirements for the new engine. the angled strips of plywood is the jig used to create the new doghouse.
foam core is cut, shaped and glued to place. It then gets several layers of fiberglass cloth and resign on both sides.
all corners and edges are shaped, glassed, sanded, filled, sanded again until glass smooth. Repeat as necessary.
A rabbit joint is cut and shaped before fiberglassing to give a water tight seal when combined with lid.
3" PVC pipe is glued into both sides then ducted to outside vents to supply engine air flow. A seat box is then fabricated over top of the vents which are then completely hidden.
The engine cover is nearing completion
A perfect finish requires many hours of meticulous sanding, filling and more sanding using progressively finer grit sandpaper.
The bottom side of one air vent. Any water that manages to get this far will fall to the bottom where the bilge bump takes care of it. The smaller pipe is the water drain for the deck hatch.
the inside corners get filled and sanded.
inside view nearing completion. There has been gel coat sprayed here for color and the next stage sanding has begun.
with the corners filling and sanded its beginning to look as though this was the way the boat had been built from the begining
