The sun is making Mary Lee into something that resembles a slow cooker. Air conditioning is not nearly enough. This week was all about getting some shade covers sewn up.

I looked around at what other people had on their boats. I liked the synthetic fabric on one boat in particular. Very light and breathable. They got their fabric at a Home Depot. I went on Amazon and searched for shade fabric. What I found claims to block 95% of UV rays. It came in 6 foot width and about as long as you wanted in 5 foot increments. I ordered two at 25 foot length.

It finally arrived. I took a piece to the boat and did a basic layout. It seemed pretty simple. I would know when it was done

I rolled it out on the ping pong table I have been using to cut out material, etc.

Next was a little sewing.

I do seem to be getting the hang of it. Grommets came next. I opted for the big plastic ones the other boater had used. Their covers have lasted over 3 years, seems good enough for me. I did have a little trouble getting some of them to snap together all the way. I finally used a large c-clamp. It snapped them together nice and tight with no effort

Then trying out my first cover.

It seems good enough. I left it a little shorter up front to facilitate going forward. Perhaps next time I will not.
  I still needed a bit more shade further back.  I had debated on making each side into one continuous piece. But...the booms swing a bit differently, and are a different height. It seemed that separate pieces may work better.

Good enough. Besides, I can always change things next time. Needs a little adjusting. Also hard to believe they are the same width. The shade makes a huge difference. The bottoms are attached with bungy cord and S-hooks. Everything for this project came up to just a few dollars over the $100 mark.

In other news. I start upholstery school July 18th(about 2 weeks).
  I will be in school a year. It is 4 days a week. About 300 miles from Mary Lee. So...once again, life will keep me too busy to spend a lot of time on Mary Lee.

The process of getting me recovered, to a point where it is finally beyond just struggling to get through each day, has been an all consuming chore(to say the least). I bought Mary Lee as a way to force the fight, so to speak. It had to be something "out of the box" that I really wanted to do.

As I finally began to see a real improvement in my recovery, I realized, that I needed to find something that I would enjoy doing. Something that could be boating related. Flexible enough in hours that it could work with boating. I also have those days when I hurt too much to do anything.

I had an interest in upholstery long before I got hurt. Liking it will make a big difference. Being able to see projects finished nicely suits me to a "T".

I think I could use sewing to fund a circumnavigation (if I so choose).

  The work continues, a step at a time. My vision was to make Mary Lee lighter and brighter. It felt like a dark cave at times. Don't get me wrong. I do like wood, but it was just too much of a good thing.

Remember this from much earlier in the blog?

This is what it has evolved into so far.

Much better.
Now for the knobs. Solid brass.

They helped.
  I have shade fabric coming in any day now. I am also just about done with the A/C box for mounting A/C to blow down hatch. Portable A/C is not cutting it.

I have a stretch of driving truck in front of me before starting upholstery school.

  A few months back, I installed a defective solar powered vent on the forward hatch. It turned out to be one of those lessons that will not be repeated :-)

I found two of these vents for quite cheap. First mistake was buying two of them. I needed to rebed the glass in both hatches as they had begun to leak.  It seemed that putting a solar vent in each one was a good idea. Only 5200 was available. Kind of a permanent sealant for what I was doing. I just figured that as long as I was careful....All would be well. My work was good. vent was not only defective, but now everything was put together with 5200.

I sealed it up with aluminum tape. When I got the time I would fix it.

  This time it would be done correctly. I thought about it. I decided installing something that would potentially leak, right above the v-berth, was not acceptable. This meant new glass. I got online and ordered polycarbonate glass. I got enough for 3 hatches. It was cheaper to order that amount.

I have been busy, so it took a while to get around to the hatch. I also was dreading the 5200 I had bedded the glass with last time. I tried cutting it out, around the edges, with a razor knife. Not so good. Keeping in mind the rubber seal below the glass. I needed to save it. I had no idea where to get another. At least on short notice.

I gave it some thought. When it does not work by hand....incorporate a power tool. I put a Dremel cutting disc in the drill. Did not work. I decided to try a cutting drill bit made for Dremel. Bullseye. It walked down the frame, pulling the sealant off the aluminum cleanly. Well...It roughed up the aluminum a little, but all that would be hidden by sealant. It was time consuming, but I got it done

Now it was time to cut out new glass. It needed to be perfect. Fortunately, I just happen to own a good bandsaw. A big bandsaw.

It made the cutting easy.

Perfect fit in the frame. I forgot to take a picture of the drill press. Holes for the handles and hinges needed to fit perfectly. I clamped the old piece on top of the new one. Put proper bits in drill press and drilled holes.

You can see them here with baling wire run through them for handles. When bedding new glass. You have to use a bead of slow cure on top of rubber seal. Set glass in with as little movement as possible. Then let it cure before doing the edge with fast cure. The clear glass made it difficult to see the edges. I put the pieces of tape on just so I could clearly see the edges. It worked great.

Finally got to seal the edges.

I put white privacy tint on it and installed hinges and handles. Everything fit beautifully. Off I went to the marina to install it.

I sat in the van watching a storm roll in. I had tapped the opening. I could only hope it held up. It poured mercilessly for over 30 minutes. The picture does not do it justice. An hour after this picture, I installed the hatch in full sunshine.

I have sun shade fabric coming in any day. I will be doing the screen for shading boat any day now. I hope it turns out as good as the hatch.