Smith Access Construction Details on Nellie D. #63

The Smith Access is a removable panel in the companionway between the pilothouse and stateroom.  The panel is part of the bulkhead separating the engine room from the head/shower areas.   It is named for Craig and Rosemary Smith, Rose Bud #34, who were the first to request this modification.  It subsequently became an OEM standard on many subsequent tugs.  Removing the panel makes it really easy to access the front of the engine.  

Open access in the companionway

The access panel is 19-1/4"w x 21"h.  It is held in place with two 2-9/16" long barrel bolts.  The access is made of a 7/16", 5-ply marine plywood.  It is faced with teak paneling--each of the panels are 2"w x 3/16"thick.  The access is framed on three sides (port, starboard, and bottom) with teak strips. A step (15/16" thick x 22-1/2w x 6-1/2"deep), supported by two gussets, is attached to the access panel.

Closed access in the companionway

Since Nellie's access was built using techniques found elsewhere aboard, it leads me to believe that her Access is OEM.  However, I cannot be certain without comparing Nellie's to a known original.  Therefore need to get the Access details  from one of these tugs:  Perseverance #32; Rose Bud #3; Kedge #43; Monkey #52; Tug E. Bear #62; Georgia J. #65; or Tortuga #69.  Then, once we know what an original looks like it will also be easier to determine the provenance of other tugs' Accesses.

Nellie's access panel

Construction Techniques Used on Nellie's Smith Access

Joint detail between removable step and the side of the companionway

1.  There are pencil lines on the panel's backside.  The lines traverse the panel's perimeter, and while varying, average about 3/8" in from the panel's edge.  I believe these lines are a transfer from the bulkhead and were used by the carpenter to cut the access panel to size.

2.  The access panel's three trim pieces are (1) glued on, and (2) vary from 1/8 to 5/16" thick.

3.  A miter joint was used to connect the bottom trim piece to the port and starboard pieces.

Pencil lines and miter joint 

4.  The tops of the port and starboard trim pieces are tapered, presumably to keep the panel from sticking because of  humidity changes.  This same joint can be found in the access panels under the settee.  There is no trim piece along the top of the panel.

Tapered tops of side trim pieces

5.  Seeing as neither the back of the access nor the back of the step is varnished, it's possible the Smith Access was varnished in place and at the same time as the companionway.  The fact that the barrel bolts are covered in varnish confirms that they, at least, were in place when the Access was varnished.

Unfinished back of step.

6.  Two 2-9/16" barrel bolts hold the access panel into the bulkhead.

Two 2-9/16" barrel bolts hold access in place

7.  The stair's two gussets (wooden bracket supports), like the treads themselves, are teak, 15/16" thick and with a bull-nosed end.  The gussets and treads are identical in color and finish too.  Each gusset is held to the tread with two fasteners in countersunk and bunged holes.  Each gusset is held to the access panel with two stainless steel, Phillips head screws, driven in from the engine room side of the panel.

8.  The back of the tread has a 7/10 miter cut (about 35 degrees).  Since this is sharper than the companionway's 6/10 (about 50 degrees) slope, the top of the tread presses tightly against the panel while the tread's underside does not. 

The tread and supporting gusset

9.  The rough opening in the bulkhead was finished with a teak jam.  The jam's corners are mitered.

10.  A bulhead mounted, teak, butt jointed, stop, with 1/2" reveal prevents the access panel from falling through the opening.

The bulkhead's jam and stop