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You're correct, Delrin is very durable. I wonder if it's as slippery as HDPE or nylon? I wonder if it matters? :) My only experience with it (that I know of!) is in small pieces inside bimini fittings.

This doesn't directly answer your question the way it was asked, but I think it answers what you're trying to do in the end... Add the new battery in parallel with your existing house battery. Now you effectively have a single battery that has twice the amp hours.

I wonder if a local community college or tech school would like to give 3D-printing that part a shot for you as a project. I don't know much about 3D... can it be done in something like polyethylene or nylon?

Agree with the above. I've only ever seen friction hinges used on plexiglass type things (gauge covers). I would use either a gas spring or even just a stainless support spring. The latter is probably the simplest solution - although the gas springs are a nicer option and you won't...

I've only ever used the Magma grills and mounts (on a number of different boats), but the mounts have an arm the holds the grill away from the boat a bit. There is an extension arm available, too -- although I never found the need for that. I never really had a problem with grease dropping...

Yeah, as noted above, you weren't given the best advice. If a stringer is compromised, that bolt/nut are just going to squash the two sides of the glass. And, epoxy resin will work fantastically with the old stuff.

If nothing on the handle, try the top side of the entire assembly - it's worth a shot. Along the lines of what Seasick said, though, now that I think about it, I recall seeing threads about this and the plastic sliders. You might try contacting the various manufacturers, as well. Garelick and...

Sometimes the white handle has the manufacturer's name on it

Sounds like a ground issue, not so much a supply issue. Add a new/second ground to the bus under the dash.

I had always thought that there was another filler board/cushion to fill the empty spot? Does the shape of the hinged bunk even match the hole? Just looking at that picture, it doesn't appear so. But you'd know better as you can see it in person. A piece of plywood and some foam cut to shape...

Incorrect. The problem was the guy sitting behind a desk at the EPA that has never boated a day in his life but insists he knows what is best. So now there was not only the carbon canister system but also a check valve in the fill hose and another check valve in the vent fitting? Ridiculous...

I'm betting that at night, when it's nice a quiet, you'll hear it easily and it'd wake you up. But it certainly can't hurt to do what you're planning, either!

I do not know what size it is, offhand, Adam. But did you verify that the sender is the issue by shorting to ground at the sender? Some of the senders have a model number right on them. If not, just pull it out and measure. Senders are a very commonly available part so any local marine store...

Thanks for the extra info. Unless something different from original was done, it's unlikely to be your battery cables, though. Check them just to be sure, I suppose. 17 years old is certainly old enough to have corrosion/connection issues, especially if in salt water. While that could be...

I'm not sure what model and year boat you have, but... First thing would be to go back and check all of your work. From what you've written, it appears this all started after you did the install so the installation is the first suspect. It is highly unlikely there is anything wrong with the...

Search for "piezo buzzer" on Amazon. There will be lots of choices for a secondary alarm - especially if you want to keep it simple. Just wire whatever you choose in parallel with the main one. You could actually just get a REALLY simple buzzer and install it somewhere out of the way...

Jersey, as others mentioned, 4 years is a long time to go without doing any maintenance. They call it "preventative maintenance" for a reason :) Keeping up with a little PM prevents (well, "helps", anyways) issues from popping up. Do you use a good fuel additive all the time? I don't know...

Johnson Pump has been around for a long time - good company.

The install is about as easy as easy gets. It's the simplest type of circuit - basically just an on/off switch. The alarm/buzzer can be put just about anywhere - but behind the dash would be ideal. Ideally, you want this to be a different sound than your Yamaha alarm sound. I would recommend...

I'm not overly concerned with hitting the top end of the RPM range, either. It's good to be at least close to it for efficiency, though. I wonder if your Explorer is lighter than my Offshore? I can hit 40 on the dot with a light load. Strange, though, because your RPM is right in line with mine.