I previously claimed that the boat project was complete, but it turns out that was a lie.
While on the lake recently, I decided I needed a small platform in the bow to kneel on when raising and lowering the anchor, tying off at the dock–or shooting a bow (the archery kind) off the bow (the boat kind).
It could also support an electric anchor winch and/or bow-mounted trolling motor if I ever decide to go that route.
I figured a full-on casting deck would be overkill, and given the small size of my boat, wasn’t sure it would be stable enough to stand on, anyway.
I did some preliminary measurements and decided a 12″ platform would suffice, still leaving room underneath to store large objects (like the 5-gallon bucket I keep my anchor and line in).
Given the cost of sheet aluminum, I wanted to be sure this was going to work, so I cut out a cardboard template and crawled into the boat to check it out.
It looked promising, so I sent away for a 2 x 3′ sheet of 3/32″ aluminum for the platform and some eighth-inch 1.5″ angle for braces.
(note: some of the links in this article are affiliate links, which means that if you click the link and buy the associated product, the vendor may pay me a fee–your cost is unaffected)
Knowing that bare aluminum would get hot enough in summer to burn skin, I also sent away for more of this blue camouflage EVA foam cover to match the thwarts (seats) in the rest of the boat.
With the help of my template, a tape measure, and a Sharpie I marked the support braces and disappeared into my garage lair to cut them out.
My sabre saw made a mess of the first cut, and the aluminum was a little thick for a Dremel cutting wheel, so I ended up cutting them with a hacksaw: nice, accurate cuts but EXTREMELY tedious. If there were more than just a couple to do I would’ve broken down and ordered an angle grinder (I’ve had my eye on this one for a while)*.
*Note: after reading even more internet reviews I eventually bought this one instead. I’ve been very happy with it so far!
I belong to the “measure twice, cut once–then file and grind repeatedly to fit” school of metalwork. I marched out to the boat to test fit my new braces.
They looked good.
Although the sabre saw failed miserably on angle stock, it worked fine on sheet aluminum. I started by sawing the sheet in half lengthwise to get the 12″ platform I wanted, then went back outside to trace the outline of the bow gunwales (rails) onto the bottom of the sheet.
About here I realized that this stuff was stout enough to render the forward support brace redundant. Reluctantly, I set that lovingly hand-carved piece aside for another project.
Back to the garage to cut the platform to size:
I did so, breaking an elderly saw blade in the process (remember, people–eye protection!). I put my last spare blade into the saw and finished up.
I marched back out and checked the fit. One end of the remaining (aft) brace protruded slightly so I marked it, then used a grinding wheel to reshape the offending part.
The platform fit was good, so I used it as a pattern to cut the EVA foam. I had to do some mental gymnastics to make sure I’d matched the bottom of the foam to the top of the platform before cutting–important because the two sides of the platform, like the gunwales they rest on, aren’t perfectly symmetrical.
Luckily–because I didn’t have enough material left over to try it again if I hadn’t–I got it right the first time.
Now it was time for assembly. I drilled holes for 5/32″ blind rivets, using clamps and unseated rivets to keep everything lined up until all the holes were drilled.
I then coated the rivets with marine silicone and seated them with my handy Harbor Freight riveting tool.
The first one I seated was in the rear right corner, closest to you in the picture above. It turned out to be too short to anchor the platform and brace to the gunwale underneath, so I drilled it back out and replaced it with a larger (1/4″) rivet. I did the same on the opposite corner.
I rechecked the fit of the EVA foam cover, peeled off the backing paper, and stuck it to the platform with the help of some heavy duty spray adhesive.
I gave it a few minutes for the glue to dry, then drilled new holes for the cleats. These needed to be further aft than before to clear potential anchor winches, trolling motor mounts, etc.
The original 2″ bolts were now too short so I used 3″ replacements, cutting off the extra with a Dremel wheel.
I gloated over my new platform/shelf/deck for a while, then vacuumed up all the aluminum shavings and put away tools.
I’d say the boat project is FINALLY finished–but we know better, don’t we?