Cockpit instruments patch job

[Charlie98117]

I thought someone might be interested in my solution to the problem of patching holes from old instruments when you change things out. I recently decided to replace my depth and knot meters with a new style multi-function display. It only needed a 3-1/2" hole and I had two 5-1/2" holes to cover.

The first solution that came to mind was to cut a piece of starboard big enough to cover the old holes and install the new display. I started trying to visualize it and it felt like a rectangle just didn't work with all the lines of the cockpit cowling. I then built a simple sketchup model with the old holes laid out. That allowed me to try some different shapes and sizes. I decided I liked one solution that simply followed the lines of the cowling. Of course then I decided that I needed to make the other side match. I've posted the before and after photos below.

 

[George Da Porge]

That's a really nice looking job! Great idea having matching panel on starboard side.
1) where did you get the starboard material?
2) how did you secure - I don't see any screws or bolts?
3) does the starboard need painting to protect it from UV rays?

 

[kloudie1]

That is a great looking job, Charlie!. I really like the way you've matched the sides..

 

[Charlie98117]

That's a really nice looking job! Great idea having matching panel on starboard side.
1) where did you get the starboard material?
2) how did you secure - I don't see any screws or bolts?
3) does the starboard need painting to protect it from UV rays?

Thanks George and Claude for the kind words. I was happy with how it turned out. Sometimes I get hung up on symmetry but in this case it seemed like I really needed to do both sides so it looked like it was supposed to be that way.

I got the Starboard panels at Tap Plastics. They're a west coast chain but they do mail order also. http://www.tapplastics.com/product/plastics/plastic_sheets_rolls/king_starboard/526 They cut to size so I didn't have to get a whole sheet. Then I just had to cut the sloped sides and then put on a quarter round edge with the router. The material is easy to work with.

I have 3 exposed stainless screws attaching each panel from the inside. I decided they could be exposed on that side without being too ugly.

As far as I know Starboard is pretty much UV resistant. I was also pleasantly surprised to find the white color was an almost perfect match to my 30 year faded gelcoat.

 

[Ralph Johnstone]

C'mon, that's the original factory instalation.

At least it certainly looks like it from here. Very nice indeed.

If the starboard has a stippled finish, it's UV resistant. I've had my Starboard motor mount sitting in the sun (what little we get here) for six years and it could pass for new material.

 

[Rick D]

Great Job! Did Something Similar...

Nice job! I had to replace a radio which had two cut outs, one for the speaker and another for the head. I ordered HDPE from McMaster-Carr, cut it and routed the edges. Used the old screw holes for the panel and added two. Made a gasket. Worked out OK. Here are photos of the original radio on the steering station and the replacement (which also has its own internal AIS and GPS).