35 TE Cockpit Sunshade

[Halcyon]

Hello all, I am starting to work on an off season project to build a sunshade for the cockpit of our 35 TE. It is a flying bridge model and I see and opportunity to have tubes telescope out from the flying bridge eliminating any framework from the gunnel. The will run roughly parallel to the green stripe and come out at the aft end where it turns.

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The mechanics of the install are easy enough except for how to make it as unobtrusive as possible when not in use. The cover, light sunbrella or screen, will come off and the tubes slide into the flying bridge. I can't find a good way to finish the exposed part.

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I hoped to make the 2" stationary tube recessed and the sliding tube would use the piece left in the hole saw as a cap for a flush fit, but there is no way i can get access from inside to do anything. I though about a 90 degree rod holder the tube would slide out of but it would require some pretty big fairing blocks and be too noticeable. A fuel/water filler cap might work. but dimensions are tight.

Right now i am leaning toward casting a round cap with the curve of the flying bridge to cover the area. Anyone out there have any other solutions/suggestions? thanks!

[Ben423]

I use plastic push-in end caps. Look up 2" plastic end caps on Amazon.

[DougSea]

I'll be watching this project with great interest!!

[Halcyon]

I like the cap idea, thanks. I'm going to order the fiberglass tube soon. My next challenge is cutting the boat, which always scares me, without chipping the gelcoat.
Does anyone have advice on hole saw type? I plan on covering the area well with painter's tape.

I have used jigsaw blades that cut on the down stroke instead of the up stroke because they were supposed to chip less. There wasn't the 'night and day' difference I hoped to see. Any hole saw advice?

I guess ill get a sharp hole saw, spin it fast and apply pressure slowly. Any advice is welcome.

[Ben423]

To minimize chipping the gelcoat try using a diamond grit hole saw. Use easy pressure and spin it in short bursts so you don't get too much heat buildup.

[Halcyon]

Well i screwed up my courage and drilled the holes yesterday, they turned out better than I expected

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Next is finishing the mounting of the stationary tube and then the canvass work

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Why are my pictures sideways until you click on them?

[Halcyon]

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Here is a mock up of the shade I did for the canvass guy. The aft orange rope is the trailing edge showing the amount of preload i want to give the tubes. The middle line is to show how the fabric will be supported from above.

The tubes I got are 1/8" wall. I am going to upgrade the inner one to 1/4" wall for a bit more stiffness.

First estimate for canvass is $1,000 for Sunbrella. Its about what I expected, not what I hoped for. Great shop with great attention to detail.


How do I adjust the rotation of the pictures? thx TD

[DougSea]

Looking good!

How far in to the bridge/outer tube does the support tube go when extended? I'm assuming at least 12-18". And how do you secure it?

Are you taking your photos on an iPhone and posting from the phone? Or from a computer?

[Halcyon]

Sorry for the lack of updates, here are a couple of pictures of the first install. It works well and is quite strong, even underway, I am going to have a sleeve installed down the centerline to help create a bit of a ridge.

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These are Iphone pictures but posted from a desktop.

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