Thank you David Th. and David T. I hope you are both doing well during these unprecedented times.

Your two comments read like echos of my own thoughts. First I would convince myself that wood soaked in epoxy and filled with stainless steel might actually be stronger than it was before. Then shortly after I would remind myself that my boat is not Speedwell of Hong Kong or Oryx so I can probably use lighter hardware.

I will look for 3/8" threaded SS rod first. If for some reason 1/2" is easier to find then I will use 1/2".

Thanks again.

Scott wrote:

I am concerned about drilling 1/2" holes in four different places on the sides of the tabernacle. The boards I used are 2" dimensional lumber which is 1.5" actual thickness.

I am trying to decide if drilling out a third of the thickness will significantly weaken the structure.

Does anyone have an opinion to share?

I think it will be just fine because you are gluing the bolts in with I imagine epoxy. So long as you get a good bond, the bolts, (threaded rod), will just become part of the timber. But this would be a good occasion to adhere to all working with epoxy rules.

I am still not sure why the sign at the store says '0.703" actual' if the nominal is 18mm (0.709") for this plywood. It seems like the 'actual' on the sign would be the nominal value.

There are clearly bigger problems in the world right now.

Evaluating risk of normal activities has become complex. For now, since our Governor has ordered everyone to 'Stay Home, Stay Safe' I am going to avoid going over to the boat storage.

I will be working on cutting and shaping plywood for the mast partners here at home today. I am not sure what I am going to do when I eventually need a tool that I left on the boat.

But yet the supplier for my mast, on the other side of the Lake Michigan, in Wisconsin, sent me an email. They claim to be able to keep up with any existing or new orders as normal. They gave me an expected ship date that is just about a week earlier than what I expected.

Daily life is paradoxical right now.

Thanks, David. I read a few of your other responses again. I think I now understand what you are recommending regarding thick disks bonded around the tabernacle.

I would expect 18mm plywood to be 0.709" actual thickness (0.708661").

Is 18mm plywood actually a little less than 18mm thick?

I have one layer of 23/32 CAT (0.703" actual thickness) dry fitted with bolts where the fore-hatch was previously located. Was it not confusing enough to sell plywood in fractional inches? Now we use a strange fraction like 23/32 and even that is only an approximation of the actual thickness? I think someone is trying to make this intentionally difficult.

Anyway for my mental accounting I am considering this one 3/4" layer above deck for the partners. I have twelve 1/4" stainless steel bolts as mechanical fasteners. I imagine they are 304 SS. Six of them run through the deck and new plywood core. The other six are through the new plywood only. I plan to use plenty of thickened epoxy to fill in any gaps in this entire assembly. I plan to add one more layer of approximately 3/4" plywood and call it done.

It did not come together exactly as I wanted but I am convinced that it will be strong.

I would greatly appreciate a review of this description and the attached photos. If possible, please let me know if you see anything that looks 'wrong' enough that you would not personally trust it.

One of the photos was taken through the plastic sheeting that I am using to keep the mess from my boat off of other people's boats in storage. Please excuse the blurry image.