So here we go. This was spread over about a year. First I made the actual top piece, then the bottom rail was made right on the boat. Then I built the gantry crane to set the top piece up there and join the two together.
I started with a table to make the mahogany ribs that are internal to the top.
Made with OSB, filled with thickened epoxy, sanded, then clear coated with epoxy again to give a nice smooth surface then waxed about 8 times so the glue would not stick to the form.
Next a large form was made that matched the same curve as the ribs. I did not take pics of that part. I have a few of the actual glue up of the top piece.
There is a layer of 1/4" luan on top and bottom. Mahogany ribs with 1/2"foam panel between them with solid Mahogany about a foot around the edges.
I used plastic nails to nail the first layer to the form. This allowed easy removal and sanding. I used a cheap Harbor Freight 18Ga. nail gun. Worked great and saved about $300 from buying a Italian gun made for them.
Later I cut it to shape and glassed it top and bottom.
