Date: 1/30/2010
Name: Scott
email: slindars@gmail.com
subject:Re: Hand Rails
I replaced my rails and installed them from the interior. As you said, the originals were installed from the top and bolted down. After putting on some many nice coats of varnish before the install, I really didn't want to drill into the wood for the plugs.Installation is definitely not easy but it's doable with one or two helpers. In my case, I went ahead and bored out all the old balsa and filled the holes with epoxy as the first step. This gave me a solid mount to screw into. Also, the chances of your new and old holes lining up is low, so new holes are bound to be in order.
I don't know if these are as strong as a top mount. I guess I'll find out one day :)
1) Drill a small hole pilot hole in each mounting location. Make sure this is square and centered.
2) Put some painters tape on the topside deck next to each side of the hole and draw a line where the hole is.
3) Put some tape on the rail mounts
4) Line the rails in their desired locations and transfer the line you made in step 2 to the tape on the rails. Now you have transfer the hole locations X-axis to the rails. This step takes a few hands to keep the rail in position. There will be some curvature of the rack and rail to deal with, making this hard to do alone.
5) WHen you think you have it all lined up, have your helper(s) hold the rail in position and then head down below with an awl. Use the awl to mark the bottom of the rails, through each of the holes you drilled.
6) Now you have the X and Y axis marked. Intersect the tape marks and the awl marks and mark your holes.
7) Drill out the holes. I used a drill press so I could hold the rails upside down and vertical with no wobble. If you are doing it by hand, rig something to keep the rails vertical so you can focus on drilling a plumb and square hole.
8) I then filled each hole with epoxy
9) Back to the boat with your helpers...
10) Mask off all of the rail locations to make clean up easier. You should already have tape on the rails from earlier.
11) Get out your sealant. I think I used 3M 4200 and butter up the deck, hole, and rails. Keep some paper towels and acetone handy for clean up
12) Drive your screws up from below so they are just protruding. This gives the holes on the rails something to "lock into"
13) Have your helpers put all their weigh on the rails and you start screwing them in. This is harder than it sounds.
14) Don't tighten them all the way. Come back a day later after the sealant has cured and finish them off to make that "gasket" seal.Good luck!
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