Thread: Dorade Box Design & Build WIP

That will look much better than the ones on the net.
For next time, the spreadsheet at post 6 of this link will give you the info to calculate the angles of the staves. You could clamp them up for gluing using masking tape - do the two halves ay once.

Originally Posted by AlexS

That will look much better than the ones on the net.
For next time, the spreadsheet at post 6 of this link will give you the info to calculate the angles of the staves. You could clamp them up for gluing using masking tape - do the two halves ay once.

I tried taping them but the curve made it awkward to get any pull without the pieces moving out of position.

For angles on sloping mitres with multiple sides I use this programme
Miter Saw Cutting Calculator I think it's pretty fool proof.

So after a few days away I've done some more to the Dorade Boxes,

I fiber glassed the insides of the cone to add strength it can be clearly seen here.
This is one of the cones cut up and a complete cone is in the background. The near left hand part is what will become the rear of the box, to the right of that is what will become the front, and the thin bit on the far right is waste, cut off to the same thickness as what will be the top.



After careful marking the centre line and cutting the cone into two parts on the bandsaw, one half needs cutting to make the front part of the dorade box. Do you like my home made gauge?



It becomes a little clearer in this pic. A simple glue up, but I had to make some wedges to keep the clamp angles correct.

Looking good Your Lordship,
Keep the pics coming.

Just needs the round cap glued on and a baffle plate inserted inside and some drain holes cut along the bottom edge and the boxes are nearly finished. So this is what they look like up to now.


In this pic you can see the glue is still wet

Looking good, nice coopering job.

What's a dorade box and the cowl do? The best I can guess is something nautical.

Originally Posted by Waldo

What's a dorade box and the cowl do? The best I can guess is something nautical.

Basically they vent a boat with an air flow through the boat keeping mould and damp out. Usually one of the cowls is pointed forward collecting wind, while the other is pointed aft acting as a suction, it's this combined action that helps circulate fresh air through the boat.

That makes sense. And here I was thinking it was a go-faster stick out of the bonnet air scoop.

Final glue up

gluing in gussets well not really gussets they are really to guide the screws into pilot holes drilled in the teak deck. In the far dorade you can just make out where I've drilled and counter sunk through the top, when the glue set properly I'll drill again from the tops down through the gussets.


You can see the drain holes or scuppers cut in the lower edge of the box in this pic.

Holes drilled out and stainless steel screws fitted

I wanted stainless steel countersunk slotted screws I didn't want to use phillips or posidrive. Now you just try finding 70mm long stainless steel slotted countersunk wood screws, these were sourced from Southern Ireland and cost a mint.


The deck they are to be fitted to has a slight curve. So on the left is a template I made, you can see a distinct curve in the lower edge. The dorade is sitting on some bits of ply that copy the curve. This means I have had to cut a slight curve into the bottom of the dorade box for it to sit perfectly.


On the left and looking tired a Plastimo dorade box with cowl. Along side my home made dorade boxes.


Similar in size was a must, the new ones have to fit within the deck guard that protects the dorade from fouling any loose sheets (rope) flying around on deck.




One turned the opposite to the other, this is how they will be normally used.


Just a good rub down with some fine wire wool and that's it they are finished.

Nice work, m'lord. Practical and attractive.

I know which is much more appealing.