Need to replace Wood Engine Cover on 1981 Sundancer 260

[Ahhspray]

I've mostly redone my 1981 Sundancer 260. Refinished Hull - 2 hand wet sandings, 1 orbital rubbing compound, 1 orbital gelcoat restorer, 1 orbital wax, 1 hand wax. Removed engine and went through it - gaskets, new manifolds, new water pump, new risers, replaced hoses, plugs etc. Rebuilt outdrive - checked for gear wear(like new), replaced all gaskets in upper and lower unit, impeller(every year), painted, new trim senders. Realigned engine and drive(yearly). Switched all lights to LED.

Boat runs great. I will try to find time to post pics of rebuild.

Now I'm into the cosmetic stuff and I'd like to replace the plywood engine cover, and the plywood that covers the gas tank. Both of these appear to be 3/4" with shallow router lines that make it look as though its strips of teak. It is BADLY delaminating and beyond repair. Was this a teak veneer originally? Can it be purchased any longer? Where? Would it be a better idea to replace with some sort of modern composite hatch? I'm open to suggestions.

Thanks in advance

 

[fwebster]

You can buy teak plywood.

You can buy teal and holly laminate plywood........real teak/holly as the op layer on plywood.

You can buy teak planking and make your own. The advantage is that you won't have any open grain wood to deal with. I recently bought several board feet of this for a similar project. :

http://www.ebay.com/itm/1-4-inch-th...721662?hash=item58cc3dc2be:g:cOQAAOSwQPlV8OAa


It is extremely nice clear grain teak quarter sawn with tongue and groove routing on one side. Get some high quality marine plywood and make your box/covers then laminate the teak to the outside using West Systems epoxy. It won't be quick, but you will have a special one of a kind that will last forever.

 

[Ahhspray]

You can buy teak plywood.

You can buy teal and holly laminate plywood........real teak/holly as the op layer on plywood.

You can buy teak planking and make your own. The advantage is that you won't have any open grain wood to deal with. I recently bought several board feet of this for a similar project. :

http://www.ebay.com/itm/1-4-inch-th...721662?hash=item58cc3dc2be:g:cOQAAOSwQPlV8OAa


It is extremely nice clear grain teak quarter sawn with tongue and groove routing on one side. Get some high quality marine plywood and make your box/covers then laminate the teak to the outside using West Systems epoxy. It won't be quick, but you will have a special one of a kind that will last forever.

Thanks for the quick reply! That looks like my best option for sure. I had looked into teak plywood but no one local carries or can order it and the shipping i was finding online didn't make it cost effective. Plus, as you mentioned, I would still have to deal with opening up the wood grain with a router which would compromise it. The suggestion to create my own laminate cover with these 1/4" teak strips is a good one. Thanks again!

 

[worzy1014]

I built one for a 1981 245 out of finished ply wood. I just coated it with Sikkens and it held up surprisingly well for not sticking a whole lot of time or money into it.

 

[Ahhspray]

Thanks Worzy1014.
Mine is still functional and I'm trying to get this boat back to its original state or better. I'm leaning towards using the teak strips since this will have the look of the original and should last longer. I appreciate your suggestion!

 

[MMcCawley]

Sorry to not answer your question but I'm curious how happy you are with the results of your gel coat. Sounds like a ton of work!
My 268 Sundancer has weathered, chalky gel coat that I've been buffing this week and I feel like my arms are about to fall off. And I'm not even half way done yet...
Would love to see some pictures when you have time to post them.

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