Hello, I have a recently purchased 1981 O'day 28. There were 4 round aluminum instrument housings mounted on the exterior bulkhead just to the right of the companionway. The holes are 4" in diameter. I removed the aluminum housings from the holes. They are fairly heavy-duty and extended about 3" deep into the 2 laygers of bulkhead. There were 4 of them, all sealed in a bit messy with some sort of sealent/caulk that had gotten dry and brittle. Now I have 4 clean holes thru the bulkhead 4 inches in diameter. I have one newer 3" instrument I'd like to install instead of the old empty aluminum cylinders into one of the 4" holes. I'm thinking of cutting andn finishing a nice peak of teak or plywood "cover" about 13 inches x 13 inches which will cover all four holes. I'll put one clean 3" hole into the cover that lines up with one of the existing holes in the bulkhead. Then I'll mount the teak "cover" over the 4 holes and seal it in good with some sort of sealer. I might put 4 screws in it, but don't think it's necessary but might help to get it on tightly. My issues at this point are: 1) Was there any structural value to those 4 heavy-duty instrument housings? If I remove them is that bad? They were made by Electro Marines Systems and are really strong, makes me kind of suspicious that maybe they are structural also. They have a heavy-duty lip that protrudes about 5/16" out so I can't put them back otherwise my wood won't be flush to the bulkhead. I could drill or router? 4" diameter countersink holes in the back of the "cover" that would fit over them, perhaps, I guess if there is value to retaining the aluminum housings. 2) What kind of plywood or wood should I use? I'll cut it with my saw and have a friend router the outer edge so it's smooth and round. I'll drill the hole. I want to stain it and finish it correctly and have it look nice well as being functional and a proper repair. Any other wisdoms? I didn't want to get into all this but had to move the only newer electronic multi-instrument somewhere. It's a Raytheon Raydata, by the way, and came with the boat. Thank you for any thoughts. dave
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Teak
I doubt there are much structural considerations in covering these holes. This is a pretty common repair. I would find a nice piece of solid teak (no plywood) and finsh it with Silkens Cetol or other good marine grade finish. Place some line organizers on the teak. Good Luck Jeff
I doubt there are much structural considerations in covering these holes. This is a pretty common repair. I would find a nice piece of solid teak (no plywood) and finsh it with Silkens Cetol or other good marine grade finish. Place some line organizers on the teak. Good Luck Jeff
do what you said
there's no problem taking out the old instruments and covering the holes with a nice piece of finished wood. I went the other direction on my 28 and just replaced 2 of the instruments with new instruments that fix exactly and installed outdoor cockpit speakers in the other (with one on the port side as well) If you can find a nice piece of teak, that would obviously be my first choice for wood.
there's no problem taking out the old instruments and covering the holes with a nice piece of finished wood. I went the other direction on my 28 and just replaced 2 of the instruments with new instruments that fix exactly and installed outdoor cockpit speakers in the other (with one on the port side as well) If you can find a nice piece of teak, that would obviously be my first choice for wood.
accept your advice, thanks
Thanks for the advice and I've located some 3/4" teak about 13" by 13" that will work nicely. I'd like to fill in old screw holes, should I use epoxy to fill in a bunch of old holes before I attach my teak cover plate? Should I put sealer in the hole I make in the teak as I put the screws in to hold the teak in place? And, I should seal the teak to the bulkhead with some kind of sealer? Sorry, just completely unfamiliar with working on boats and want a good repair. Thanks, dave
Thanks for the advice and I've located some 3/4" teak about 13" by 13" that will work nicely. I'd like to fill in old screw holes, should I use epoxy to fill in a bunch of old holes before I attach my teak cover plate? Should I put sealer in the hole I make in the teak as I put the screws in to hold the teak in place? And, I should seal the teak to the bulkhead with some kind of sealer? Sorry, just completely unfamiliar with working on boats and want a good repair. Thanks, dave
My choice was...
...Star Board. I removed the old instruments from the bulkhead of my Nonsuch 30 and used a piece of 3/8" Star Board with beveled edges to cover the holes. I cut a new hole for the single multi instrument and it looks great and I don't have yet ANOTHER piece of teak to varnish. Cheers, Bob
...Star Board. I removed the old instruments from the bulkhead of my Nonsuch 30 and used a piece of 3/8" Star Board with beveled edges to cover the holes. I cut a new hole for the single multi instrument and it looks great and I don't have yet ANOTHER piece of teak to varnish. Cheers, Bob
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