Pilothouse Windows

Pilothouse sides, windows roughed in

Pilothouse Windows

Slightly warmer temps have us back at outdoor work.

One of our favorite parts of boatbuilding is getting to the window cutouts. They transform a valley into a vista with a puff of sawdust. Our imaginations are taxed at a lower bracket, and we can practically see beyond our shed walls and across water.

After the sides were installed and framed, we cut the corners with a 3in hole saw. Then, with a flush cut router bit, cut the perimeters.

Note the hole cut is a skosh offset from framing
to avoid damage.

This is what results. If we were real router jockeys, we might cut all the way to the tangents, right through that little pointy bit.

But we're not. It's durn hard to see what we're doing for fine starts and stops, so we bail a bit short and clean up by hand.

With a sharp knife, trim each edge to fair, then bring the middle flush. Takes about a minute per.

BTW, this is a Mora knife. I prefer their laminated blades, but they're no longer dirt cheap. Their non-laminated, stainless blades are still great and can be found for under $10!

Here's the completed curve, shaved fair.

Once all are complete, it's ready to sand and finish before the plexi-glass gets installed.

These will be sliding windows, maybe with a double-glazed panels. Down in the forward cabins, they'll be double paned and fixed.



*****

Growing up, Anke was never allowed to sit on the family's kitchen counters. So naturally, sitting on the counters is an integral part of our pilothouse/galley view.

From here, we get a 360deg view and a vantage forward, over the mid-deck. We'll be installing the primitive, remote steering system from SLACKTIDE. It works well enough that we only have to leave shelter if setting or reefing sail. Mostly, we hope she sails herself.

Meanwhile, we sit on our counters, looking out our windows, the green world flowing by...

Navigating Foamy Seas of Fabric

That's some chalkboard, "Einstein"!

Every point on the mollusc is treated as a space-point, and every material point which is at rest relatively to it as at rest, so long as the mollusc is considered as reference-body.

From Relativity by Albert Einstein

Navigating Foamy Seas of Fabric

To those of us used to the Newtonian absolutes of 'rigid' plywood, turning to fabric is to enter the undulating reaches of Einstein's relativistic universe.

Fabric is visibly flexible. Roll out a strip of it, and it may lay straight. Or it may curve like a banana, one way or the other. Or snake both ways. It can fold, hump and pucker, too, leaving its two dimensional plane. Hang an end over an edge, and it has the tendency to siphon itself to gravitational equilibrium. Fortunately, in the era of synthetic threads, we don't have to worry about shrinkage in the temporal dimensions!

Foam - at least the cushy sort - isn't much better.

To tame the mollusc, we need an external reference... in our case, the straight edge of a long-ish table in the caretaker's cabin. Line up one edge of foam or fabric with that (and keep it aligned) and smooth it flat, and we've imposed a reference edge and a planar surface. After that, it's just a matter of layout, cut, fold, and sew to the lines.

Of course, folding is something we seldom do to plywood.

Spatial visualization of flat stuff folding into shape tries the imagination. Some folks have developed it more than others. But really, unless you're a genetic sport, it starts out hard. Practice makes perfect. Like learning a new dance, the first attempts tread on toes. First one is a mind-bender; second is not half-bad; third a piece of cake.

Mostly.

As in all things, we looked for the KISS approach. No piping, fancy shapes, zippers (velcro, instead), etc.. We sewed a single join around the perimeters. At the corners, where excess gathers, we fold under as one would wrap a package in paper. Here and there we tack any floppy excess with thread and needle, or dart it out, as seems indicated.

A confused sea

Tips n' Tricks (from the Ignorant):

• Bobby pins can be used to secure hems for sewing... not as prickly as pins.
• Hot Melt Glue can often be used to tack things together... be sure to press the 'dots' flat before they cool!
• Woof and Warp (the long and cross threads in fabric) are freebie square and parallel... follow them and it's hard to go wrong.
• An Electric Knife cuts foam cleanly... the double bladed, turkey carvin' kind.

Dinette, cushions, left
Settee cushions behind
Folded Bunk (upside in), with ice blanket showing
Loose fit will snug up when finished with Hook n Loop

Salon Seats and Backrests:

These were all variations on a theme. Simple boxes in simple wrappers.

The only complication was that we wanted to use a second type of fabric for inboard faces. It was from SLACKTIDE's bunk, and we like to carry a bit forward from each boat. Also, we under ordered the blue nylon seconds by about a yard.  8/


Bunk:

Pretty simple in retrospect, but we burned a lot of braincells on this one.

First, our 60in cloth has to be joined to cover the 72in x 78in bunk. A longitudinal join, we figure, runs up where our sensitive upper bodies lie, like a miniscule bolster. A transverse join runs across our shins/calves, and seems much less intrusive. So that was our choice.

Our foam is open cell. Moisture travels downward and condenses at the first cool surface (the plywood bunk deck, in this case) and soaks the mattress from the bottom up. One semi-fix is to raise the mattress on a low lattice for airflow under, which evaporates and transports moisture. But also, we laminate a layer of close cell foam on the upper surface. This keeps moisture to the upper surface where it can harmlessly evaporate. Plus it firms the total foam, which we like for sleeping.

Next problem is that, to access the under-bunk storage, the bedding has to fold in half around the long axis. If the foam is a single block, this is AWKwaaaaard! But if we cut the foam into two blocks, then, if not compressed equally, we get a cliffy rift along the centerline.

Our solution was to cut the foam in two along the long centerline, then glue the close cell foam in a contiguous sheet to both surfaces, crossing the divide. We left the first foot to either side of the divide unglued.

Our cover unfolds to resemble a couple of bicycle panniers; two pockets topped by a flap that tucks between open and closed cell foam into that first, unglued foot.

The entire cover is made from a single strip 'scrolled' from one flap, down the divide face, across one bottom face, up the side face, all across the top face, down the other side face, across that bottom side, up the divide face and tucked between foams. End faces sewn together pillow-case style along the mid, end face (not shown). Whew!

 

The fabric and closed cell foam form a longitudinal hinge for folding the mattress over. Meanwhile, since it spans the divide, it eliminates that cliffy ridge. Result... works like a charm and comfortable!

Looks like we made harbor.

Mid-Deck: Puttin' on the Lid

I went to the Kitchen, lifted up the lid,

Stole me a mess o' that shortnin' bread.

I wunk at the pretty girl an I said,

"How'd ya like to make a li'l shortnin' bread?"

-- From Shortnin' Bread

Mid-Deck: Puttin' on the Lid

Well, mid-winter progress has been slow. Not steady. Slow.

Our original plan was to button up the exterior of the boat by the end of autumn, then spend winter puttering on the (heated) interior while coursing through sail and upholstery projects at the cabin. But no. Our boat remains unenclosed and therefore unheated, and the cabin has been teeming with construction personnel. In other words, both our work environments have been only available in fits and spurts.

Sigh.

Still, we've managed to creep the mission a bit.

I favor two kinds of deck in a Triloboat; flat, sloped decks at the ends (more of these in future posts), and a curved, constant section mid-deck.

Sheet materials, when curved, assume one of two sections; conic and section-of-cylinder. When longitudinal  edges are parallel sections-of-cylinder result.

In the mid-ground (2nd and 3rd from front) are two bulkhead arcs
defining the shape of the mid-deck.
The darker hued one is the template, from thin ply.

A box barge/scow from sheet materials lends itself to parallel sheer lines, both in plan and profile. Consequently, section-of-cylinder decks are the easy choice. If a curved sheer is desired, fauxworks are possible, but multiply complexities through adjacent structures.

All longitudinal lines across such a deck run flat, straight and true, with layout and construction ultra-KISS. The sections of such a deck (as if sliced like a loaf of bread) are constant... a single template can be used for the deck arc and the hull which it covers. Transverse members follow identical curves at any point along the deck's length. In this case, the outboard foot on each side was allowed to run straight, resulting in sloped planes. This eases bending sheets, and simplified the one foot wide side decks along the Pilothouse.

For this boat, we're using ply-foam-ply (aka SIP) construction. Since heat rises, insulated overheads are especially effective, and - if nowhere else - make an attractive return on investment in warmth and condensation avoidance.

Generally speaking, in any arced, composite deck, the lower panel will be the thicker to equal thickness, relative to the upper. Both are working in compression, and the lower (following a smaller radius, tighter curve) bears most of the weight. The top layer mostly has to be thick enough to stand up to point loading (dropping an anchor, say) and spread loads without deforming the filler material (foam) between layers.

In our case, we've been happy with 1/2in lower and 1/4in upper, separated by 1 1/2in foam. This saves 25% of deck ply weight for about 125lbs, all of which is high in the hull. That's the equivalent of a small adult on deck.

We sized the first layer, using the mid-line as reference, and trimming to land on bulkheads. Full-width edges land on the sheer logs, with about an inch of overlap (1in/ft of crown). Bulkhead upper faces are insufficient landing for single layer construction, but by the time all layers are added in ply-foam-ply, there's plenty of total surface area. This layer is glued to the hull structures with 3M5200. We glued, and fastened along the mid-line, then bent the ply down and fastened, working our way outboard.

Glue was to have been water-based TiteBond III, but it has been defeated by winter cold/wet. So Gorilla Glue (Liquid PolyUrethane) is doing the job. We try to work at temps above 35... despite warming the glue, if the ply is too cold, GG goes to heavy honey consistency, and it sucks up considerably more. Bad news both in terms of supply and $$.

We're using the left hand option.
Note the But over the wide 2x framing overhanging the hull side.

Longitudinal framing is 2x4, with 2x5 along the outboard edges. Framing provides nailers for the ply sheets, helping to keep close contact between ply and foam. Down the mid-line, the port and starboard sheets butt along one of these. Outboard, they overlap the 2x5 which is extends outboard to form eaves.. later, strips will be added outboard to complete the ply run to eave edges. Caps will be added to the 2x5's outboard edges to provide a stable basis for the eventual fabric/resin coating.

Transverse framing is built up from two layers of 3/4in (= 2x). We glued these up, using the salon bulkhead as a jig, then cut them to fit between longitudinals.

Slightly over-bent to spring back about true.
We put a nail at one end to maintain position while allowing sliding as ply strips bend to spec.
Note the plastic to protect the blkhd from glue drip.

We cut the foam with a Japanese saw (very thin blade; cuts on pull stroke), checking with a Quick-Square to ensure a right angle cut. Most framing ended up plus or minus 1/16in. We went for tight, but not too tight fits. They seem to work best when considerable pressure is required to force them down into place, but not so much that they arc up and away from the lower ply. Foam edges compress slightly, and the glue acts as a lubricant. No kerfing was required to accommodate the bend (may need some for the tighter radius Pilothouse).

Note: Be sure not to push the dry foam all the way down... it's WAY hard to get back out!

We dry fit each piece, averaging the differences at each end, and used a rasp to fine-tune any over-size. Any small gaps are filled by the expansive Gorilla Glue. We had one biggish gap (about 3/16in), which we filled with a glued slice of foam.

At assembly, we smear glue onto the upper face of the lower ply and framing edge faces. Insert foam. Smear upper face of foam and framing. Position upper layer of ply (prefit and marked for nails), and fasten from the mid-line, working outboard. Clock starts ticking with the first glue, and we have about 20 minutes per 'sheet' (including foam).

If there's any gaposis (squishy release sounds when you depress ply between frames), extra measures are needed. Clamps can't work... an extreme possibility is a long screw driven through ply-foam-ply and into a 2x block on the low face. Work fast, though, as the glue will be setting up, making any gaps permanent. To date, we've managed to use live weight; simply squatting in place until the glue has set up. Good time to make up for hasty, glue-job irritability.

So... as of this writing, we're half-way on the mid-deck. Two weeks (and maybe more) private time is on our horizon. All we need is a little more, unseasonable warmth.

Who knows? Maybe we'll get a lick of work in!

Completed to s'brd, foam fitted port and aft, empty bays awaiting foam port and fwd.

The Winter of Our Discontent... Well... Sorta

Sunrise at a decent hour.

Now is the winter of our discontent
Made glorious summer by this son of York;
And all the clouds that low'r'd upon our house
In the deep bosom of the ocean buried. 
-- William Shakespeare from Richard The Third


The Winter of Our Discontent... Well... Sorta

Still waiting on 'glorious summer'. But gotta admit that winter has its own pleasures.

Our project has come a ways since last you heard from us (posting on that, soon), but we're slogging against low temps and wet. Meanwhile, many of the winter chores are coming due on the caretaker side of our arrangement (sawing wood in freezing weather). Construction personnel come and go, with varying degrees of unforeseen social and site-related interactions. The holidays sapped our will with temptations and gratifications.

In short, we're 'slow as molasses in January'.

But we're in a gorgeous spot, overlooking two of the shoal, intricate waterways we love. To the southwest is unlimited line-of-sight to the horizon. To the west and south snow enshrouded peaks and ridges soar over the dark conifers of our foreshore. The animals of winter delight in the paradise we all inhabit, feasting, socializing and playing in sheltered nooks.

So we're picking away, as we can. The bottom is complete and coppered, and the boat lowered off the jigs. The mid-deck is soon to be completed. We've started upholstery projects near the fire. Even managed one coat of clear on the salon and bunk overheads.

Meanwhile, a batch of spruce wine turned out tasty. Our fire is warm and our hearts joyous.

Tipping a cup o' kindness your way, dear Readers, and wishing you well for the New Year!

Love,

Dave and Anke


PS. This just in... a head-to-head of the Split Junk Rig we're planning vs Bermudian. Thanks to RWL at volkscruiser.blogspot.com for the heads up!

Interior Ready for Paint

Overview from forward

Interior Ready for Paint

Our latest strategy was to finish up the interior and get some paint on to hold our gains against encroaching winter. Well... the interior's complete - barring a few deets that can wait for spring - but its sub-freezing and frosting inside the shed! Paint will have to wait for the next thaw or an operational stove, whichever comes first.

So next come the decks. We hope.

In lieu of paint, we've tarped the hull over to keep the ply as dry as possible. But before we did, we took advantage of the rare sun for a few pics...


Kitty-corner Over-views

We're generally using the same layout as LUNA, which worked very well for us.

The entire living spaces are open to one another, as much as possible, to allow a roomy feel, long views with big angles out the windows, and a more or less contiguous social space.

The cook is 'part of the party', and there's plenty of room for a sous-chef. One to a few can lounge in the bunk (Anke likes the little bit of social remove, there)... participating while not being in the thick of it. If someone has had enough and wants to turn in, a curtain can screen it off.

The large side windows (much smaller one LUNA) keep the walls from closing in, opening the interior onto the world at large.

From forward, the main cabin divisions are the bunk, salon and galley (under the raised pilot house).

Looking aft and port
Salon dinette, and galley counter and wetlocker/head on the right

Looking aft and starboard
Salon settee, and galley stove and workbench on the left

Looking forward and starboard
Galley stove, salon leanbank and s'brd bunk leanbank on the right

Looking forward and port
Galley counter, salon dinette, bunk platform and port leanbank on the left

The Bunk

The bunk itself is 6ft6in long by 6ft wide, with wall to wall storage, under, accessed by large platform/hatches. Port and starboard are two full length leanbank/lockers, and an approximately 2ft square window. The 'blank space' over the leanbanks and ahead of the windows will eventually become bookshelves.

Let the Wild Rumpus begin!

Salon

This word embarrasses me, actually... sounds so yottie! I'd call it a 'living room', but it seems no more so than the others. Now that Anke has (5ft8in) standing headroom, it's not even a 'sitting room'. So, in the interests of tradition and clear communication, 'salon' it shall be.

To port is a near 3ft wide dinette ('table') and seat/lockers which makes down into a generous bunk for one or a snug fit for two.

Windows above, the entire length
Note the cleats running around the gangway for platform

Opposite is a 6ft6in settee (see 'salon'... it's really a 'sofa' or 'couch') /locker, with a leanbank as per the bunk. The settee locker lid is hinged to a narrow flap... the lid can be slid inboard with the flap laid flat for a full, 2ft single bunk.

Settee... note hinged flap outboard of the seat

Lid slid inboard with flap down to make bunk

Not shown is a removable sole... normally this lies flat against the inside face of the hull. It can be raised to the cleats lining the gangway, and, with the dinette made down, the entire area becomes a single platform, contiguous with the bunk platform. Great for slumber parties or spread-out projects!


Galley

 The galley is the most complex space, and remains that with unfinished business.

To starboard and forward is a woodstove mounted in an alcove formed by an L-shaped woodbox. Wood can be added at the top and removed from the bottom. In winter, it holds about a week's worth of wood (at least for previous stoves with smaller fireboxes).

Starboard and aft is a 4ft x near 3ft workbench, with storage under (yet to be arranged). Anke's herb garden (she's got the green thumbs) will live on the workbench top, but can be moved for sun or convenience.

Stove to left with L-woodbox behind and under
Workbench to the right, with storage under

To port and forward is the dedicated galley area, with a 4ft x near 3ft counter, extended by a near 3ft x 2ft flip up counter (see below). Forward will be a double sink, with one basin inboard and the other outboard (these will be built from ply... the designer order a stainless sink too big to fit!). Under will be miscellaneous stowage for big, liquidy stuff (water, fermenting wine, gallons of vinegar and soap, etc.) with cunning storage as needed (the hinged flap is for skinny storage inboard of the sink... toothbrushes?).

Port and mid-galley is under-counter storage with a door closure. The door will have a rack of a dozen quart jars with various dry-goods. Low down is an open bin for large, seldom accessed pots and the like (canning pressure cooker and supplies, hand mill spares, ???... maybe some spuds, too). Over this will be a set of four drawers - two shallow, two deep, and 18in wide x 2ft6in long - to be divvied as seems fit.

Port and aft is the wet locker/head topped by a flip up counter. When horizontal, this extends the galley counter, when flipped vertical, it makes a wall for the 'head' (see Getting aHead for a full description).

Galley port side and gangway seen from forward

The gangway has an 8in raised sole, with room for quart jars under. Aft is the battery box, which also forms the first of three steps (incomplete). It extends from the inboard face of the hull 18in upwards (10in rise over the sole) x 2ft7in wide x 18in long. Should have plenty of room for the battery and electrical panels with room to spare for tools.

 *****

So there you have it... our humble home to be.

Getting aHead

By Jo Hudson
from the SEARUNNER Construction Manual by Jim Brown

Viewed objectively there is nothing more absurd than the usual sea-going toilet of the modern production yacht. What expense and engineering, what a profligate use of space and materials, what a baroque concoction of pipes and valves and pumps and skin fittings, what a sop to over-developed human sensitivities, all for the purpose of transferring a small amount of matter a distance of about twelve inches, from here on the inside of the hull, to there on the outside of the hull.

-- From Mingming and the Art of Minimal Ocean Sailing by Roger D. Taylor


Getting aHead

To date, Anke and I have never built an enclosed Head into one of our boats.

Our boats are small to begin with. Partitioning a chunk off for a room that's in use for a few scant albeit imperative minutes a day seems to needlessly cramp our style. The walls block the view (high crime, in our book) and crowd the remaining space.

Anke and I are mostly alone together, and quite comfortable with our nitty gritty. When friends come along... let's just say things are 'up close and personal'.

So a little more privacy would accommodate the sensitivities of our guests, not all of whom are as... um... earthy as others.

On the other hand, the one thing we've always longed for but never had was a Wet Locker; a place to let our raingear drip dry. Heads are traditionally not too bad for that purpose, though their ventilation is often wanting.

To that end we came up with the following:

Note the Head/Wet Locker at the lower, right (port, aft),
outboard of Companionway steps.

What we're looking at is a row of coat hooks along the wall, outboard of a section of flip up counter. This allows space for hanging outdoor gear, especially raingear, where it can drip harmlessly to a well-sealed floor.

The counter, when horizontal, extends the galley counter by (about) 3ft. It also doubles as the port, pilothouse seat, from which we can steer the boat under cover (workbench shares the same role, opposite).

When flipped vertical - hinged along its forward edge, it locks into position to form a partial wall. A curtain may be drawn across the inboard face, and voila! A semi-enclosed head!

It's not as isolated as the typical Head, but visual privacy is ensured. It's positioned under a pilothouse window, so ventilation is better than most. It's still a bucket affair, but a two bucket compost system isn't out-of-the-question. (Here's a great resource on DIY composting toilets from one of our readers).

Set-up and -down take but a matter of seconds, for those in haste.

So this has been a paper possibility for a couple of years, now, and I've been drawing them into Triloboat StudyPLANS. But if anyone's built one, I haven't heard... until now.

So here's a sneak preview of the as yet untried system, at the roughed-in stage. Stay tuned for trial and error to come!

Looking aft into to the portside Galley.
Head/Wet Locker aft.

Looking kitty-corner at Head/Wet Locker

Anke holding counter vertical...
will eventually have a barrel bolt into a small, partial wall outboard
(Mirror on the underside?)

Oh God!

  

Scrounged hinges...
installed 'upside down' to reduce gluteal hang-up
(the pronounced hinge curl could otherwise bite us in the A**
while sitting on counter)

Sitting Pretty
(and able to look out,, 360deg)

Search Keywords: head marine head nautical head head alcove tiny house bathroom compact bathroom

Insulating the Hull: Retro-fit SIP

Adding inboard layer of 1/4in ply
Next space to my right has fitted foam ready and waiting
Two areas to my right, the inboard face of the hull is exposed
This guy oughtta be wearing his ear protectors!

Insulating the Hull: Retro-fit SIP

Anke and I recently finished insulating the hull cabin spaces, using ply-foam-ply aka SIP (Structural Insulated Panel) construction.

I can think of five, basic options for SIPping hull sides:

1. Join pre-fabbed SIP panels to make sides
2. Build one skin, with framing, then add the second skin in one go
3. Build one skin, with framing, then add second skin in select areas
   
   ...Join finished sides to bottom and bulkheads.



4.  Build inboard skin, framed and joined to bottoms and bulkheads, then add foam and outboard skin in one go
5. Build outboard skin, framed and joined to bottom and bulkheads, then add foam and inboard skin in select areas

We decided the first three had some problems for us.

Building remote, we didn't expect to have the muscle to raise heavy-ish, completed sides into place. Short-handed lifting with mechanical assist takes time and ingenuity.

The first presents framing challenges, since many framing pieces internal to the SIP extend beyond a single panel. No go.

Two is better, and straightforward. But all transverse bulkheads and dividers meet the inner skin...

To join sides to bulkheads, in this approach, fasteners must be on the long side (to reach through the SIP with enough left for 'bury') - expensive. Alternatively, shorter fasteners may be inset and plugged - time consuming. Tape n' glue with judicious use of resin welding (tape n' glue minus the tape) is an elegant solution, but messy, toxic and generates lots of heinous garbage.

Method three addresses these problems, but there's a quandry. Transverse dividers must either:

• Contact the outer layer (complicated) - SLACKTIDE, with her minimal furnishings, was manageable, but with the many sub-girder furnishings this round, this approach gets out of hand.
  
• Attach inboard of the SIP - If using a cleat, then that needs something in the SIP to fasten into (double framing). Resin welding looks preferable, in this latter case, but with resin's downsides.

Method four is intriguing, but we were ultimately uncomfortable with many of its questions and consequences.

For example, which to put outboard; the thicker layer or thin (1/2in vs 1/4in ply)? Thicker outboard makes for better protection against the cruel world. But inboard, it affords more structural integrity and a strong backup to outer skin failure.

Our window framing (2x stock) doubles as structural reinforcement AND we want to see its clear, red cedar in the interior. This implies we want it on the inboard side of the thicker layer.

So number five it is - Retro-fitting foam and ply on the inboard face of a fully functional hull. QED. All framing (2x2 or 2x4) doubles as spacers for 1 1/2in foam (blue-board). Light 'firring' (non-structural spacers) from 1x2 fills in where there's no framing.

A big advantage of this approach is that all transverse panels (bulkheads, partial bulkheads and furniture faces) meet the structural skin of the hull. Not only is this strong, but short (generally 1in fasteners) suffice for the 1/2in ply skin.

Another is that most, if not all inboard panels are relatively small, bite-sized glue jobs. Divide and conquer, with every juncture fully visible until completed (i.e., don't have to try to remember where we put that framing inside the SIP!

So how did it go? Pretty durn well!


In our salon and bunk areas, the surface of seats and the bunks are all the same height. In the galley, all the counter levels are the same height. In a box barge, this implies parallel spaces between framing. Foam and the inner layer of ply can be cut into strips, then lopped off for the necessary length... efficient in both time and materials! Even over the end-curves, we start with the same strip for a given space, and cut it down further to match the odd shape.

We used TiteBond III through the summer months, switching to Gorilla Glue as the days grew cold and damp. This is supplemented by DAP Alex Plus ('siliconized acrylic'... basically a latex window caulk) to fill any larger voids. For whoppers, consider wood or foam shims, and for small ones, consider a bead of (expansive) Gorilla Glue.

TIP: For nice, tight FOAM fits, consider using a tick stick (a stick which is held in place and lengths 'ticked' directly from the structure, then transferred to the material). This is much more reliable than measuring. The tighter the better to exclude air.

 TIP: PLY is easier to fit (and caulk) if it's loose around the edges. Too much accuracy, and you risk wasting time needlessly fighting the material into place. Consider erring on the side of looser.

Standard Operating Procedure is to dry-run and prepare. Take a deep breath. Then...

Slather glue on the inboard face of the hull and framing / firring faces (those abutting the foam). Insert foam working toward one corner to release air (may have to relieve air pressure with a knife, inserted through the foam and given a slight twist). Slather glue on the outboard face (foam side) of the inner ply cover. Nail into framing / firring.

TIP: Consider penciling guides to framing on the inboard face of the inboard layer - 1x along this edge, 2x along that one, nailer line across here, butt-strap along there, etc.. Once you've covered it over and started nailing, it'll be these or your memory to guide you.

We use this order to ensure that plywood faces interior to the SIP are encapsulated by glue, in case of voids. Moving quickly (especially in the case of Gorilla Glue) allows both layers to be completed in one go, avoiding clean-up between layers.

At this point, press outboard near the mid-point of foam areas. If you hear sucky noises as you press and release, you've got a void. Use one or more struts / blocks / wedges (creatively) to provide and hold pressure. Consider that some glues are setting up, and this step must be completed with dispatch.

TIP: Before starting the glue job, consider pre-arranging strut materials to fit the situation. You may not have time to improvise once glue is setting up!

Once the glue is set up, remove struts and caulk edges around the ply with DAP or your favorite trim-in-a-tube.

TIP: It's messy, but we like to fillet the caulk with a blunt (gloved) finger. This forces caulk deep into any gaps, and feathers the edges along the (now concave) 'bead', making for easy cleaning down the road.

E basta!

In theory, the result is a very rigid, insulating wall with no internal voids to collect moisture or dry-rot.

2x2 Framing along top and right edges, 1x2 'Firring' along left and bottom edges
Struts with protective pad and wedge...
Blocking at other end (not seen) adjusts length against opposite wall or furnishing

Notes:

In these sad and diminished times, little is as it seems. Consider checking your dimensional lumber for accurate sizing (same thickness as your foam). Too thick and you get voids over the foam (plane or saw your stock to size). Too thin and you get voids over the framing (shim or caulk over framing). Either are a major pain where you sit!

Red cedar seems to be an great choice for framing. It's strong, light, glues well and is naturally rot resistant. Works easily and smells good. Be careful of breathing the dust, though... it will sensitize you faster than most (the allergic kind, not the SNAG kind).

Consider laying out your panels on paper, figuring the most efficient way to to get what you need from what you have on hand. It's time consuming, but conserves material and/or $$. Can be done at home of an evening.

Gorrilla glue seems to spread adequately at a rate of about 18oz / 4ft x 8ft / one side. It gets sluggish and inefficient to spread in cool to cold weather. We warm it in warm water to about body temperature to keep it viscous. Still sets down to 20degF (about -10degC)... as low as we've tried it. Feels a little more brittle if applied in the cold, though. Not sure if or how that affects bond. No failures to date, though, on wide-area bonding.

Cutting foam with a table saw produces neat, accurate edges. But when cuts are too wide for our max fence setting, or for short cross-cuts, we use a japanese saw (thin blade, cuts on pull stroke). We walk a quick-square along as a visual guide for near perfect, right angle cuts. The edge is less smooth, but doesn't appear to matter. A whiz might be able to use a circular saw, but I end up destroying one or both sides of the cut.

TRICK: It's easy to lose track of framing that has been SIPped over. Say you want to mount a sturdy row of coat-hooks... can't just screw into 1/4in ply and foam! Before it's covered up, put a galvanized steel nail at each end. Later, when you've forgotten what's in the wall and where, use a magnetic 'stud finder' (they come small) to locate them. Fasten anywhere along the line between them.

TRICK: The method we use calls for a lot of notches in plywood around framing.To lay out notches, keep small blocks of your framing stock handy. Lay onto plywood in the correct orientation and trace one side, then reposition and trace the other. Much faster than squares and measurement, and more accurate.

TRICK: For the deep end of a three-sided notch, cut the two sides with a saw. Layout the backline between cuts on the back face, and slice deeply along from both faces with a sharp knife. Grasp the 'tab' between cuts and bend back and forth until it breaks out. Clean up with your knife, if necessary.

TRICK: If glue sets up and you believe you have a void, drill into it at one edge with a bit sized for your glue bottle, and one or two spots about six inches away. Inject Gorilla Glue until it wells out your other holes. Repeat as necessary, covering the whole problem area. Plug holes after glue has set up (if you plug right away, the expansive glue will likely blow your plug). It helps to cut your nozzle square for this job. Old caps may be saved and used for this.