Installing a Lewmar D1 Rope Clutch

[...3TacksontheWater]

On the old to do list is installing Lewmar's D1 clutches on the cabin top. My handrail is a four (4) loop version so there should be room for the two (2) line model. I read on Stingy Sailor that he used 3.5" long bolts to mount his on his older C-22. For those of you who have the New Design, does this measurement hold true? I will be ordering 6mm Stainless Steel Bolts but would like to confirm the length needed before I drill holes in the cabin. Thank you in advance for your replies.
George

 

[ambler]

I installed cam cleats on the cabintop behind the grab rails. Mine is 1983 so I can’t help with the bolt length. I drilled the holes oversize and filled with epoxy. I didn’t notice that one of the holes (outboard on the starboard side) passed through an open space between the cabin top and the headliner in the cabin. I kept pouring in more expoxy trying to fill it and then discovered the epoxy had run out and dripped inside the cabin. I did fill it by allowing small amounts to firm up and then add more. I’m not sure there is a wood core in the cabintop so oversize drilling the holes may have been overkill.
Jack

 

[AaronD]

My distant memory is for an 1981, so perhaps not relevant to your New Design. And it is a very distant memory; but if I recall correctly, the cabin roof thickness varied, and I ended up using at least 2 different lengths (and still different lengths for deck organizers and other hardware elsewhere on the deck).

Some builders buy overlong bolts and cut them off with a Dremel (after mounting; approximately flush with the nut). 3.5" should be more than enough if you want to go that route. I took the approach of stocking the shop with way too much 316 stainless, so I have bolts on hand of almost any useful size...

 

[ShawnL]

On my '72 there was foam in the cabin top. Everywhere except the sliding companionway hatch. That had plywood. The foam didn't look like it filled everything up -- there were air-spaces, and nooks where it was just empty space. In general, it's layer of fiberglass, foam, another layer of glass and then whatever they made the "head liner" out of. It could be fiberglass, but doesn't feel like it. It's not really vinyl either. I just finished doing a complete re-core on mine as it was leaking (likely a lot longer than I realized) and everything inside was soaked and rotten.