Wooden Boat VHF Radio Installation

[Woodnaut]

I'm installing a fixed-mount VHF radio and don't want it too close to the compass, but it needs to be close enough to reach while underway. The best place for it is right in the center of the dash but this could be a problem. The windshield opens in the middle for entering and exiting the boat, so the center of the dash gets bumped around quite a bit. Also, the anchor is usually tied off on the forward deck and the excess line is wrapped around the handy cleat that's in the center of the dash.

Nevertheless, the center of the dash is the best place for it, so I've decided to fully recess the radio and cover it with a piece of 1/4" Lexan for protection. To do this, I need to increase the thickness of the dash in this area to about 3", and then use a router to cut a rectangular hole to mount the radio. I'm using a piece of plywood with a rectangular hole as perfect guide for the router. By moving the router around inside of this guide, a hole of the exact size needed will be cut.

To give the dash the total thickness required, a couple of mahogany blocks have been cut to size and mounted in the correct location behind the dash.

This picture shows the first pass that was made with the router. I'm using a 1/2" straight plunge bit.

After a few more passes of the router, the full 3" thickness of the dash has been cut through.

The plywood template was removed, its guide hole was enlarged, and then it was carefully repositioned on the dash. A few more passes of the router was made to counter-bore a larger hole. This time the cut did not go all the way through. A ledge was formed in the bottom of the hole that the radio will mount against.

 

[Woodnaut]

Re: Recessed VHF Radio Installation

Re: Recessed VHF Radio Installation

The plywood template was again removed, enlarged, and repositioned for a final cut. This last cut is only 1/4" deep and will provide the recess for the protective Lexan cover (which is 1/4" thick).

Here is a photo of the dash from the back side.

I don't think I own a power tool that can trash out the garage faster than a router. I have a 3 HP Milwaukee.

The block that was attached to the back of the dash comes off and everything gets a coat of epoxy. Everything (including the dash) is made from mahogany which is very rot resistant, but the epoxy provides additional protection.

The plywood guide was last used to cut the recess in the dash for the protective Lexan cover. I then used this guide to cut the exact same sized hole through another piece of plywood. This picture shows the hole that was just cut in the second piece of plywood. I'll now use this plywood to trace a pattern on the Lexan.

Below you can see a Lexan cover that has been made from this pattern. Also in the picture are the magnets that will be used to hold the cover in place. The Lexan has been drilled in 4 places to accommodate a magnet.

 

[Woodnaut]

Re: Recessed VHF Radio Installation

Re: Recessed VHF Radio Installation

This photo shows two Lexan covers with the magnets epoxied in place. One cover is solid and the other has been drilled with some holes for the speaker, and a few larger holes for access to the volume and squelch knobs.

This photo shows the two Lexan covers. The solid one has been completely painted to match the dash, while the other one (with the holes) was painted just around the edges to hide the magnets. The blue tape is on the back side and was used to mask the center during painting.

The block has been reinstalled behind the dash and everything has been painted. This photo shows the installed radio. It also shows four places where a short piece of steel has been embedded into the dash which will line up with the magnets. This steel will be covered with more epoxy, sanded smooth, and then repainted.

This photo shows a small stainless steel tab I made to protect the microphone wire. It serves two purposes. First, it provides a smooth radius for the microphone wire to wrap across as it is pulled out for use. Secondly, it prevents the microphone wire from pulling off the protective Lexan cover. Notice that the embedded steel pieces have been epoxied, sanded and painted.

This picture provides a better view of the radio mounted in the dash. The GPS is almost 11 years old but it still supports a NMEA Ver. 2.0 data output. I wired this in to the radio which was able to read the position data.

Here is the finished installation. This photo shows the Lexan cover with the holes in it in place. These are rare earth magnets and are much stronger than I expected. Fortunately they do not visibly affect the compass. They hold the cover firmly in place, and since it is recessed flush with the front of the dash, it can't be easily dislodged.

 

[Woodnaut]

Re: Recessed VHF Radio Installation

Re: Recessed VHF Radio Installation

This was the location of the old FM antenna that was on the boat.

A new block with fabricated with all of the correct angles to fit in perfectly and hold the new antenna just right.

Here's a picture of the finished dash. This photo shows the Lexan cover with the holes in place. I decided to hang the microphone on the back of the dash to try and keep it out of harm's way. (We'll see how handy that actually turns out to be...)

Here's a photo of the dash with the solid cover over the radio. Either the solid cover or the one with the holes will provide the required protection, but the solid one looks good. I should be able to bang and bump it, as well as hang the anchor line on the cleat as I did before.

 

[Woodnaut]

Re: Wooden Boat VHF Radio Installation

Here is a view of the installation from behind the dash.

 

[DJ]

Re: Wooden Boat VHF Radio Installation

VERY NICE! I remember your hull extension project. Nice boat.

You are a perfectionist! Great work!