broken thru hull

[Hookup1]

Yeah, 5200's tensile strength is stronger than the bond between gelcoat and fiberglass... which you unfortunately found out.

Plastic is tough to bond to... will the "glue" be the only method of attachment? Or can you attach it mechanically?

Both. 3M4000UV and 7 - #6 oval head screws 1" from the end, 10" apart 62" overall. Cleaned up nicely so no gap under track. Costa does it this way on all their enclosures.

 

[Hookup1]

Not in my book

Thru-hulls may need to come out at some point... damage, preventative maintenance, hose replacement, etc.

Never a problem. Works every time on the plastic ones.

 

[DennisG01]

Both. 3M4000UV and 7 - #6 oval head screws 1" from the end, 10" apart 62" overall. Cleaned up nicely so no gap under track. Costa does it this way on all their enclosures.

That should work just fine. Put some of the 4000 in the hole/on the screw heads for a little added security.

 

[DennisG01]

Never a problem. Works every time on the plastic ones.
View attachment 31135

How do you keep the hole saw centered? Gently brace it as you go... or maybe wedge a wooden plug into the hole?

 

[Hookup1]

How do you keep the hole saw centered? Gently brace it as you go... or maybe wedge a wooden plug into the hole?

The small ones I hang onto the drill and get it started. The mushroom is big enough. Wooden dowel for guide is a good idea!

Large holes or ones that were drilled out the wrong size I use two saws.

 

[DennisG01]

The small ones I hang onto the drill and get it started. The mushroom is big enough. Wooden dowel for guide is a good idea!

Large holes or ones that were drilled out the wrong size I use two saws.
View attachment 31136

Hmmmm... I think I'm going to put that double hole saw trick in my mental toolbox!