Clearing the Way for a New Pilothouse Counter

One thing I have learned while restoring Hunky Dory is that even a project that sounds simple—such as replacing a countertop—can involve half a dozen other systems.

The pilothouse counter supports the chartplotters, compass, engine controls, CruiseAir controller, spotlight control, Fusion controller, AIS switch, VHF speaker, electrical outlets, and a large collection of cables. Before replacing the counter, I first had to determine how all of those things could be removed or temporarily relocated without creating an even larger project.

Preparing the New Panels

I began preparing the new countertop panels at home. In June, I laid the mahogany-veneer panels across our family-room floor so I could decide how they should be positioned.

I wanted the grain patterns to run in the same direction, with the curved portions of the grain pointing forward. I arranged the panels until the grain and seams looked reasonably consistent, then marked each panel’s planned location with blue painter’s tape.

Over the next several days, I trimmed the excess veneer from the edges, rough-sanded the edges of the larger panels, and sanded the fronts and backs with 120-grit paper. That left the panels ready for sealing and eventually installing aboard Hunky Dory.

Clearing the Counter

Before I could remove anything permanently, I had to clear years’ worth of things from the pilothouse counter. I sorted the important items into a white plastic bag labeled “pilothouse stuff” so they would stay together during the project.

A few things needed to remain accessible, including the cellular modem, door keys, and the key used to open the freshwater-fill inlet. Everything else was removed or stored elsewhere aboard the boat.

The next major step was removing the old flat chart cabinet from the starboard side of the counter. I first unscrewed and removed its lid, then pried off the rear top piece. Once I started taking it apart, I discovered that much of the cabinet’s framing had been assembled with nails rather than screws.

A few taps with a hammer followed by some careful work with a claw hammer allowed the three frame pieces to come apart fairly easily. I saved the pieces for now, although I do not plan to reinstall the cabinet.

Removing and Labeling the Electronics

I then removed both Garmin chartplotters. Before disconnecting anything, I labeled each chartplotter as port or starboard and marked the corresponding cable bundles. Taking a few extra minutes to label everything should save a great deal of confusion when it is time to reinstall the equipment.

The compass came out next. The compass itself could be lifted directly out of its housing by pulling a small spring-loaded knob at the front. Once the compass was out, I could reach the mounting screws and remove the housing from the counter.

I also removed the mounting screws for the spotlight controller, Fusion controller, and VHF-radio speaker. Those items still have wiring attached, so I am working through how best to disconnect or temporarily relocate each one.

The chartplotter cables present their own challenge. My current plan is to enlarge the existing cable opening so the connectors can drop below the counter without being cut or disassembled. After the new counter and console are installed, I should be able to pull the cables back up and reconnect them to their labeled chartplotters.

Working Around the Engine Controls

The engine throttle and gear controls may be the most complicated part of the project. The control assembly will lift above the counter after removing four mounting screws, but disconnecting and later reinstalling the mechanical cables would create a considerable amount of additional work.

I am considering dividing the new countertop panel so that a narrow removable section meets the larger panel through the center of the openings for the engine controls and CruiseAir controller. That could allow me to fit the counter around the existing controls without disconnecting all of their cables and wiring. Most of the seam would be hidden by the equipment once everything is reinstalled.

I still need to work through the AIS silent switch, electrical outlets, CruiseAir controller, Fusion controller, spotlight controller, VHF speaker, and several cables entering the counter from the port side. Each wire and connection will be photographed and labeled before it is moved.

A Visible Step Forward

The new counter is not ready to install yet, but this was an important and very visible step forward. The old chart cabinet is gone, the chartplotters and compass have been removed, and most of the counter has been cleared.

For a project that has spent a long time in the measuring, veneering, sanding, and planning stages, it was satisfying to finally begin taking the old installation apart. The next phase will be finishing the equipment removal, sealing the new panels, and working out the final fit around the controls.

Like many projects aboard Hunky Dory, the real challenge is not simply installing something new. It is finding a way to improve the boat while respecting its original construction—and making sure everything still works when it goes back together.