PILOTHOUSES
Adding or rebuilding a pilothouse can fundamentally change how a small sailboat or trawler is used by providing weather protection, additional interior space and a more functional helm. The projects below cover pilothouse design, planning and construction, including full-size pattern making, modifying existing cabin structures, building with Coosa Board, fiberglass and epoxy, creating curved roofs and hardtops, installing windows and integrating the finished structure into the boat. These projects range from adding a compact pilothouse to a small sailboat to rebuilding and modifying larger trawler pilothouses using modern composite construction.
Building a Composite Pilothouse for a Small Sailboat
This project shows the complete transformation of a Compac 16 into a pilothouse sailboat using lightweight composite construction. Starting with full-size Coroplast patterns, I build the pilothouse primarily from Coosa Board using epoxy, fiberglass and screw-and-glue construction techniques. The finished structure incorporates custom plexiglass windows and reuses the boat’s original companionway hatch while opening the cabin to create considerably more usable interior space. The project demonstrates how a properly proportioned composite pilothouse can transform a small trailerable sailboat without overwhelming the original boat.
Designing a Pilothouse for a Small Sailboat
Before building a pilothouse on a small sailboat, the proportions and relationship to the existing boat need to be worked out carefully. In this project, I design a custom pilothouse for my Skipper 20 using deck measurements and full-size cardboard mockups to evaluate height, width, windshield rake, cabin camber and how the new structure follows the existing lines of the boat. The mockup provides a simple way to refine the design before committing to Coosa Board, fiberglass and epoxy construction—and helps avoid the dreaded Ugly Boat Syndrome.
Evaluating a Sailboat for a Pilothouse Conversion
Not every small sailboat is a good candidate for a pilothouse conversion. Before modifying my Skipper 20, I inspect the hull, deck, cabin structure, engine well, drainage and existing modifications to understand the boat I’m starting with. The assessment also considers the boat’s proportions and original construction before answering the larger design question: does adding a pilothouse improve the boat, or is it better left in its original configuration?
Boat Trailer Tongue Extension for Shallow-Ramp Launching
Some trailerable boats are difficult to launch at shallow boat ramps because the trailer cannot be backed far enough into the water without putting the tow vehicle at risk. In this video, I show how I solve the problem by building a removable boat-trailer tongue extension that allows the trailer to travel farther down the ramp while keeping the truck safely on dry pavement. I cover the basic design, materials, cost and setup of the extension and explain how trailer geometry affects launching. The project provides a simple DIY solution for launching trailerable sailboats and other small boats at shallow or poorly designed ramps. Episode coming soon.
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