On older wooden boats, most rot damage originates from the windows and decks—often the Achilles' heel of classic wooden vessels. Freshwater intrusion from aging, unsealed wooden window frames and decks leads to dry rot, which can spread far beyond the initial entry points and into the boat’s structural framework.
The older Chris-Craft Constellations were particularly notorious for three major areas of water intrusion:
Given the size of this boat and the challenges of securing covered moorage, we set out to develop a long-term solution. The goal was to reengineer these areas for complete water resistance, eliminating the need for regular maintenance of seams while ensuring long-term preservation and structural integrity.
The design was simple; the work was not. We rebuilt the decks, carefully addressing any rot, then epoxy-fiberglassed the new decking to the superstructure and cap rails, eliminating all caulk joints. To improve drainage, we installed two large deck drains, routing rainwater through a dedicated through-hull at the waterline.
To prevent water intrusion, we designed stainless steel window pockets that channel rainwater away and out through a dedicated through-hull, keeping the new wood framing completely insulated from moisture. For the pilothouse, since the existing window frames were well-protected and in good condition, we reinforced them with fiberglass for added longevity.
The portlights presented a unique challenge, particularly in the aft-most openings, where rainwater tended to pool. To solve this, we raised the interior window height by ¾ of an inch and rebuilt the framing with a slight rake, allowing water to run off rather than pool against the portlight.