From the start I wanted to do something different with the cockpit. I spent lots of time looking around on the internet and decided on a combination of the features I liked best, pointy and round. I thought rounding the rear of the cockpit would make sense visually and ergonomically. One of the things I hoped to avoid was an uncomfortable hump, created by the combing, when sitting on the deck. The design I've settled on solves this problem.
Making the curved beams:
First I drew everything in full scale to make sure it looked right and to provide a pattern for the bending jig. I used 3/4" veneered MDF for the jig as I had some scraps laying around the shop. The jig should be designed to compensate for some spring back. It is difficult to get this right the first time as spring back varies with material and thickness. A coat of wax on the jig prevents the epoxy from sticking.
I used four pieces of mahogany, 3/16" x 1 5/8" x 32"+, for each curve. The final thickness is roughly 3/4". The pieces will finish at 1 1/4" in the other dimension but must be oversized to accommodate the curve of the deck.
Spring back was a bit more than I expected, but workable.
Fitting the curved pieces provided an interesting challenge. I clamped them in place to capture shape of the deck and was able to use my stationary sander to rough out the finished shape. I usually prefer to have the work as close to the finished dimensions as possible before gluing, however, in this case I think it will be easier to machine the bevel after the pieces are permanently attached.
The end of the curve will be flush with the inside of the combing when everything is finished.
With this work complete I can move on to varnishing the in interior.
