Patching bulkhead instrument cutouts

Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com

I like your first option. - that's what I do. Although I don't re-cut the hole, but rather use the hole to mark the plywood piece for cutting to fit the hole. I used Okoume plywood of the same thickness as my bulkhead. (13 plys) Cut a piece that fits in fairly snug, then epoxy in place using the West System 610 tube mixed epoxy. On the exterior I used Epoxy appliance paint, 2-3 coats after sanding the area smooth.. On the interior I left the wood natural with an epoxy skin coat. NOTE - Epoxy that thick will get incredibly hot during curing, may catch on fire, and will certainly crack and shrink. dEmO From: Ca… [at] yahoogroups.com [mailto:Ca… [at] yahoogroups.com] On Behalf Of Kirk Grier Sent: Monday, September 20, 2010 12:56 PM To: Ca… [at] yahoogroups.com Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com<mailto:kgg%40kirkgrier.com>

Kirk, Same question on this thread. A couple of ideas as well http://forums.sbo.sailboatowners.com/showthread.php?t=122875 Joe From: Kirk Grier <kg… [at] kirkgrier.com> To: Ca… [at] yahoogroups.com Sent: Mon, September 20, 2010 3:55:53 PM Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com

Ha Ha ! I put a B&G instrument insert and then covered it with a B&G cover. 18 years later it is still there. My best, Mike From: Kirk Grier <kg… [at] kirkgrier.com> To: Ca… [at] yahoogroups.com Sent: Mon, September 20, 2010 12:55:53 PM Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com ------------------------------------ Yahoo! Groups Links http://docs.yahoo.com/info/terms/

I have been mulling the same problem, but am trying to maintain exterior appearance without having to repaint the whole area. One thought. I have not tried it yet. How about the plastic deck plates that have a access disk that screws into a larger circular ring. Install the part externally, and unscrew the center disk and install the tach. With any luck, you can find a size that covers the outer hole in you bulkhead, but also fits the inner part (tach or display or whatever). I suppose a plywood backing plate would be needed to provide some strength. Just a thought. Cheers Charlie From: Ca… [at] yahoogroups.com [mailto:Ca… [at] yahoogroups.com] On Behalf Of Kirk Grier Sent: Monday, September 20, 2010 3:56 PM To: Ca… [at] yahoogroups.com Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com ------------------------------------ Yahoo! Groups Links

do you need a porthole there? Or maybe one of the prefab storage boxes with a door? just an idea, not sure if location is good for that. HH From: Kirk Grier <kg… [at] kirkgrier.com> To: Ca… [at] yahoogroups.com Sent: Mon, September 20, 2010 12:55:53 PM Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com

I did the exact same thing on mine.. In my case someone had installed speakers Right next to the bulkhead mounted compass, this with an obvious effect. I had an uncorrectable deviation on the compass.. They had to go. You will need: Small can mould release wax Small pot white gel coat Hardner Glass finish tissue Glass Matt (General repair) Pigment kit Layup resin Hardner Cheap disposable brushes (NOT foam). Piece of blue foam Insualtion Sheet of Mylar (heat bonding stuff) Acetone for cleanup (of boat) Gloves 800 - 1200 wet or dry Painters tape Nice warmish day! This is what I did; Removed the speakers and discarded ( I hate the noise when sailing). On both sides I may a refrence mark on the inside of the hole (arrow) and offerred up a piece of marine ply to the inside same thickness or there abouts to the orginal. Now with a pencil trace the hole onto the ply and also match and mark the reference point. Cut out each circle and identify which hole it belongs to,( you may have to trim slightly. Now on the bulkhead, bevel the edges slightly and clean up removing any grease, flaking paint and leaving the bevel a little rough. dont bevel to heavily. Now to the outside. Fabricate a solid and smooth backer from something like the 2 inch blue insulation foam (Home depot). Obtain a mylar sheet, I used the heat bonding machine sheets (wallmart) and cut a good sized piece to cover the hole. Wax up this sheet with a mould release wax (smooth side) dont use car wax. Now place the mylar over the hole (wax side down) and tack into place with a little tape. get it tight as possible, no wrinkles! Place the foam block over the Mylar and jam it into place. For this I used my boat hook pole against it and the transom. Now mix up a little Gel Coat resin with pigment to get a close as match to the original, dab a little on the bulkhead to confirm. It will clean off with a little acetone. One word about adding pigmnet.. VERY SPARINGLY !! thats two words but you get the idea. Use a toothpick to add the colour to the base gel coat and mix well. Once happy with the colour mix the appropriate measure of hardner and from the inside paint the mylar sheet and into the edges with a good coat, but dont ladle it on! let it CURE! Repeat the gel coat proceedure again to get a solid colour! Let it CURE !!! dont Mess with it. Next offer some cut to a size JUST larger than the hole, Glass finish tissue into the hole, Mix up resin and hardner and use just enough to wet out and get it worked into the cracks. Let it CURE! Repeat above with some Glass matt, just enough resin to wet out. Let it CURE! Now trim down ply to fit the now glassed hole comfortably and mix up your favourite Polyester filler with hardner. Butter up the ply face evenly, and edges and offer the ply into the hole. Working in until level with the inner bulkhead. If it squidges out leave it to be proud, until firm, but not set. You can then trim off the excess with a sharp knife and leave to CURE.. Once cured all over remove the backing foam and Mylar, It should peel of clean and you will or should have a smooth allmost matching finished that can be feathered in with some 900 wet or dry. for the best in Plastic supplies, try TAPPlastics on the web.. Hope that helps ! SteveM --- On Mon, 9/20/10, Husar, Charlie [USA] <hu… [at] bah.com> wrote: From: Husar, Charlie [USA] <hu… [at] bah.com> Subject: RE: [Cal_Boats] Patching bulkhead instrument cutouts To: "Ca… [at] yahoogroups.com" <Ca… [at] yahoogroups.com> Date: Monday, September 20, 2010, 8:56 PM I have been mulling the same problem, but am trying to maintain exterior appearance without having to repaint the whole area. One thought. I have not tried it yet. How about the plastic deck plates that have a access disk that screws into a larger circular ring. Install the part externally, and unscrew the center disk and install the tach. With any luck, you can find a size that covers the outer hole in you bulkhead, but also fits the inner part (tach or display or whatever). I suppose a plywood backing plate would be needed to provide some strength. Just a thought. Cheers Charlie From: Ca… [at] yahoogroups.com [mailto:Ca… [at] yahoogroups.com] On Behalf Of Kirk Grier Sent: Monday, September 20, 2010 3:56 PM To: Ca… [at] yahoogroups.com Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com ------------------------------------ Yahoo! Groups Links

I had this same situation... what I did is have peices of lexan (sp?) cut to fit over the holes. To size them I broght the old instuments down and used those for templates. Obviously put a bit of adhesive around before screwing them in place. Pre-drill the screw holes. Added great light to my galley and quarter berth. Good Luck Greg P36-2 Cal 34 III ----- Original Message ----- From: Kirk Grier To: Ca… [at] yahoogroups.com Sent: Monday, September 20, 2010 3:55 PM Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com

Simply take some Starboard or white NSF Grade cutting board material, found at ROSS Stores for about 4.99. I would cut it to the shape of the new instrument and oversized to cover the old hole. If it is cut clean and routed drilled and countersunk it may be a solution. Mark ----- Original Message ----- From: svadas To: Ca… [at] yahoogroups.com Sent: Thursday, September 23, 2010 3:35 PM Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts I had this same situation... what I did is have peices of lexan (sp?) cut to fit over the holes. To size them I broght the old instuments down and used those for templates. Obviously put a bit of adhesive around before screwing them in place. Pre-drill the screw holes. Added great light to my galley and quarter berth. Good Luck Greg P36-2 Cal 34 III ----- Original Message ----- From: Kirk Grier To: Ca… [at] yahoogroups.com Sent: Monday, September 20, 2010 3:55 PM Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com __________ Information from ESET NOD32 Antivirus, version of virus signature database 5474 (20100923) __________ The message was checked by ESET NOD32 Antivirus. http://www.eset.com __________ Information from ESET NOD32 Antivirus, version of virus signature database 5474 (20100923) __________ The message was checked by ESET NOD32 Antivirus. http://www.eset.com

Thanks for all the suggestions! I decided to install a portlight, the Lewmar size 0 is just a bit larger than the overall dimensions of the two holes. I have often thought it would be nice to be able to look out into the cockpit when the hatch boards and hatch were closed, and also provide some additional controllable ventilation. On 9/23/2010 4:49 PM, Mark Alan Stahnke (MAS Consulting) wrote: > > Simply take some Starboard or white NSF Grade cutting board material, > found at ROSS Stores for about 4.99. I would cut it to the shape of > the new instrument and oversized to cover the old hole. If it is cut > clean and routed drilled and countersunk it may be a solution. > Mark > > ----- Original Message ----- > *From:* svadas <mailto:Sv… [at] optonline.net> > *To:* Ca… [at] yahoogroups.com <mailto:Ca… [at] yahoogroups.com> > *Sent:* Thursday, September 23, 2010 3:35 PM > *Subject:* Re: [Cal_Boats] Patching bulkhead instrument cutouts > > I had this same situation... what I did is have peices of lexan > (sp?) cut to fit over the holes. To size them I broght the old > instuments down and used those for templates. Obviously put a bit > of adhesive around before screwing them in place. Pre-drill the > screw holes. Added great light to my galley and quarter berth. > Good Luck > Greg > P36-2 > Cal 34 III > > ----- Original Message ----- > *From:* Kirk Grier <mailto:kg… [at] kirkgrier.com> > *To:* Ca… [at] yahoogroups.com > <mailto:Ca… [at] yahoogroups.com> > *Sent:* Monday, September 20, 2010 3:55 PM > *Subject:* [Cal_Boats] Patching bulkhead instrument cutouts > > Greetings, > > Not sailing but boat repair how-to ... > > I have replaced my (2) 4.5" round Signet instruments & 3" tach > and now have > holes in the bulkhead between cockpit and interior to patch. I > have a couple > ideas, but thought I would ask the list if someone has already > done this and > how. The boat has fading exterior LP paint, and interior wood > strip liner, so > refinish is not my main concern. > > My two basic choices (other than screwing Starboard over the > holes) appear to be: > > 1) cut a wood patch to fit the existing hole, perhaps beveling > the edges of > both and making the round hole square first, then glass in. > > 2) placing a framing structure into / across the hole, and > then filling with > thickened epoxy resin or the stranded reinforced body filler. > > Kirk > Cal 2-34 Footloose > Ventura, CA > > -- > Kirk Grier > kg… [at] kirkgrier.com <mailto:kgg%40kirkgrier.com> > > > > __________ Information from ESET NOD32 Antivirus, version of virus > signature database 5474 (20100923) __________ > > The message was checked by ESET NOD32 Antivirus. > > http://www.eset.com > > > > __________ Information from ESET NOD32 Antivirus, version of virus > signature database 5474 (20100923) __________ > > The message was checked by ESET NOD32 Antivirus. > > http://www.eset.com > -- Kirk Grier kg… [at] kirkgrier.com

Cal 36's have a fixed portlight that allows a view of the cockpit on the port side next to the instrument panel, it is nice, opening with screen would be even better. HH From: Kirk Grier <kg… [at] kirkgrier.com> To: Ca… [at] yahoogroups.com Sent: Wed, October 6, 2010 6:43:20 PM Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts Thanks for all the suggestions! I decided to install a portlight, the Lewmar size 0 is just a bit larger than the overall dimensions of the two holes. I have often thought it would be nice to be able to look out into the cockpit when the hatch boards and hatch were closed, and also provide some additional controllable ventilation. On 9/23/2010 4:49 PM, Mark Alan Stahnke (MAS Consulting) wrote: >Simply take some Starboard or white NSF Grade cutting board >material, found at ROSS Stores for about 4.99. I would cut it to >the shape of the new instrument and oversized to cover the old >hole. If it is cut clean and routed drilled and countersunk it >may be a solution. >Mark > >----- Original Message ----- >>From: svadas >>To: Ca… [at] yahoogroups.com >>Sent: Thursday, September 23, 2010 3:35 PM >>Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts >> >> >>I had this same situation... what I did is have peices of >>lexan (sp?) cut to fit over the holes. To size them I >>broght the old instuments down and used those for >>templates. Obviously put a bit of adhesive around before >>screwing them in place. Pre-drill the screw holes. Added >>great light to my galley and quarter berth. >> >>Good Luck >>Greg >>P36-2 >>Cal 34 III >> >> >> >> >>----- Original Message ----- >>>From: Kirk Grier >>>To: Ca… [at] yahoogroups.com >>>Sent: Monday, September 20, 2010 3:55 PM >>>Subject: [Cal_Boats] Patching bulkhead instrument cutouts >>> >>> >>>Greetings, >>> >>>Not sailing but boat repair how-to ... >>> >>>I have replaced my (2) 4.5" round Signet instruments & 3" >>>tach and now have >>> >>>holes in the bulkhead between cockpit and interior to >>>patch. I have a couple >>> >>>ideas, but thought I would ask the list if someone has >>>already done this and >>> >>>how. The boat has fading exterior LP paint, and interior >>>wood strip liner, so >>> >>>refinish is not my main concern. >>> >>>My two basic choices (other than screwing Starboard over >>>the holes) appear to be: >>> >>>1) cut a wood patch to fit the existing hole, perhaps >>>beveling the edges of >>> >>>both and making the round hole square first, then glass >>>in. >>> >>>2) placing a framing structure into / across the hole, and >>>then filling with >>> >>>thickened epoxy resin or the stranded reinforced body >>>filler. >>> >>>Kirk >>>Cal 2-34 Footloose >>>Ventura, CA >>> >>>-- >>>Kirk Grier >>>kg… [at] kirkgrier.com >>> >>> >> >>__________ Information from ESET NOD32 Antivirus, version of virus >>signature database 5474 (20100923) __________ >> >>The message was checked by ESET NOD32 Antivirus. >> >>http://www.eset.com >> __________ Information from ESET NOD32 Antivirus, version of virus signature database 5474 (20100923) __________ The message was checked by ESET NOD32 Antivirus. http://www.eset.com -- Kirk Grier kg… [at] kirkgrier.com

Cal Cruising 36's have a larger, opening portlight with screen. nice light and airflow. see attached. Reggie To: Ca… [at] yahoogroups.com From: he… [at] sbcglobal.net Date: Wed, 6 Oct 2010 22:35:05 -0700 Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts Cal 36's have a fixed portlight that allows a view of the cockpit on the port side next to the instrument panel, it is nice, opening with screen would be even better. HH From: Kirk Grier <kg… [at] kirkgrier.com> To: Ca… [at] yahoogroups.com Sent: Wed, October 6, 2010 6:43:20 PM Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts Thanks for all the suggestions! I decided to install a portlight, the Lewmar size 0 is just a bit larger than the overall dimensions of the two holes. I have often thought it would be nice to be able to look out into the cockpit when the hatch boards and hatch were closed, and also provide some additional controllable ventilation. On 9/23/2010 4:49 PM, Mark Alan Stahnke (MAS Consulting) wrote: Simply take some Starboard or white NSF Grade cutting board material, found at ROSS Stores for about 4.99. I would cut it to the shape of the new instrument and oversized to cover the old hole. If it is cut clean and routed drilled and countersunk it may be a solution. Mark From: svadas To: Ca… [at] yahoogroups.com Sent: Thursday, September 23, 2010 3:35 PM Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts I had this same situation... what I did is have peices of lexan (sp?) cut to fit over the holes. To size them I broght the old instuments down and used those for templates. Obviously put a bit of adhesive around before screwing them in place. Pre-drill the screw holes. Added great light to my galley and quarter berth. Good Luck Greg P36-2 Cal 34 III From: Kirk Grier To: Ca… [at] yahoogroups.com Sent: Monday, September 20, 2010 3:55 PM Subject: [Cal_Boats] Patching bulkhead instrument cutouts Greetings, Not sailing but boat repair how-to ... I have replaced my (2) 4.5" round Signet instruments & 3" tach and now have holes in the bulkhead between cockpit and interior to patch. I have a couple ideas, but thought I would ask the list if someone has already done this and how. The boat has fading exterior LP paint, and interior wood strip liner, so refinish is not my main concern. My two basic choices (other than screwing Starboard over the holes) appear to be: 1) cut a wood patch to fit the existing hole, perhaps beveling the edges of both and making the round hole square first, then glass in. 2) placing a framing structure into / across the hole, and then filling with thickened epoxy resin or the stranded reinforced body filler. Kirk Cal 2-34 Footloose Ventura, CA -- Kirk Grier kg… [at] kirkgrier.com __________ Information from ESET NOD32 Antivirus, version of virus signature database 5474 (20100923) __________ The message was checked by ESET NOD32 Antivirus. http://www.eset.com __________ Information from ESET NOD32 Antivirus, version of virus signature database 5474 (20100923) __________ The message was checked by ESET NOD32 Antivirus. http://www.eset.com -- Kirk Grier kg… [at] kirkgrier.com

Hi Kirk, Any chance you could post a picture or two? I'm looking for a similar solution and curious as to how it turned out (inside/outside) Joe From: Kirk Grier <kg… [at] kirkgrier.com> To: Ca… [at] yahoogroups.com Sent: Wed, October 6, 2010 9:43:20 PM Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts Thanks for all the suggestions! I decided to install a portlight, the Lewmar size 0 is just a bit larger than the overall dimensions of the two holes. I have often thought it would be nice to be able to look out into the cockpit when the hatch boards and hatch were closed, and also provide some additional controllable ventilation. On 9/23/2010 4:49 PM, Mark Alan Stahnke (MAS Consulting) wrote: >Simply take some Starboard or white NSF Grade cutting board >material, found at ROSS Stores for about 4.99. I would cut it to >the shape of the new instrument and oversized to cover the old >hole. If it is cut clean and routed drilled and countersunk it >may be a solution. >Mark > >----- Original Message ----- >>From: svadas >>To: Ca… [at] yahoogroups.com >>Sent: Thursday, September 23, 2010 3:35 PM >>Subject: Re: [Cal_Boats] Patching bulkhead instrument cutouts >> >> >>I had this same situation... what I did is have peices of >>lexan (sp?) cut to fit over the holes. To size them I >>broght the old instuments down and used those for >>templates. Obviously put a bit of adhesive around before >>screwing them in place. Pre-drill the screw holes. Added >>great light to my galley and quarter berth. >> >>Good Luck >>Greg >>P36-2 >>Cal 34 III >> >> >> >> >>----- Original Message ----- >>>From: Kirk Grier >>>To: Ca… [at] yahoogroups.com >>>Sent: Monday, September 20, 2010 3:55 PM >>>Subject: [Cal_Boats] Patching bulkhead instrument cutouts >>> >>> >>>Greetings, >>> >>>Not sailing but boat repair how-to ... >>> >>>I have replaced my (2) 4.5" round Signet instruments & 3" >>>tach and now have >>> >>>holes in the bulkhead between cockpit and interior to >>>patch. I have a couple >>> >>>ideas, but thought I would ask the list if someone has >>>already done this and >>> >>>how. The boat has fading exterior LP paint, and interior >>>wood strip liner, so >>> >>>refinish is not my main concern. >>> >>>My two basic choices (other than screwing Starboard over >>>the holes) appear to be: >>> >>>1) cut a wood patch to fit the existing hole, perhaps >>>beveling the edges of >>> >>>both and making the round hole square first, then glass >>>in. >>> >>>2) placing a framing structure into / across the hole, and >>>then filling with >>> >>>thickened epoxy resin or the stranded reinforced body >>>filler. >>> >>>Kirk >>>Cal 2-34 Footloose >>>Ventura, CA >>> >>>-- >>>Kirk Grier >>>kg… [at] kirkgrier.com >>> >>> >> >>__________ Information from ESET NOD32 Antivirus, version of virus >>signature database 5474 (20100923) __________ >> >>The message was checked by ESET NOD32 Antivirus. >> >>http://www.eset.com >> __________ Information from ESET NOD32 Antivirus, version of virus signature database 5474 (20100923) __________ The message was checked by ESET NOD32 Antivirus. http://www.eset.com -- Kirk Grier kg… [at] kirkgrier.com

Hi Joe, I will when I get it installed. I have some domino's to get done first. Probably a month or so. The portlight arrived and I think it will work out quite well. Kirk On 10/8/2010 7:43 AM, Jake Tanley wrote: > Hi Kirk, > > Any chance you could post a picture or two? I'm looking for a similar > solution and curious as to how it turned out (inside/outside) > > Joe > > > ------------------------------------------------------------------------------ > *From:* Kirk Grier <kg… [at] kirkgrier.com> > *To:* Ca… [at] yahoogroups.com > *Sent:* Wed, October 6, 2010 9:43:20 PM > *Subject:* Re: [Cal_Boats] Patching bulkhead instrument cutouts > > Thanks for all the suggestions! I decided to install a portlight, the Lewmar > size 0 is just a bit larger than the overall dimensions of the two holes. I > have often thought it would be nice to be able to look out into the cockpit > when the hatch boards and hatch were closed, and also provide some > additional controllable ventilation. > > On 9/23/2010 4:49 PM, Mark Alan Stahnke (MAS Consulting) wrote: > >> Simply take some Starboard or white NSF Grade cutting board material, found >> at ROSS Stores for about 4.99. I would cut it to the shape of the new >> instrument and oversized to cover the old hole. If it is cut clean and >> routed drilled and countersunk it may be a solution. >> Mark >> >> ----- Original Message ----- >> *From:* svadas <mailto:Sv… [at] optonline.net> >> *To:* Ca… [at] yahoogroups.com <mailto:Ca… [at] yahoogroups.com> >> *Sent:* Thursday, September 23, 2010 3:35 PM >> *Subject:* Re: [Cal_Boats] Patching bulkhead instrument cutouts >> >> I had this same situation... what I did is have peices of lexan (sp?) >> cut to fit over the holes. To size them I broght the old instuments >> down and used those for templates. Obviously put a bit of adhesive >> around before screwing them in place. Pre-drill the screw holes. Added >> great light to my galley and quarter berth. >> Good Luck >> Greg >> P36-2 >> Cal 34 III >> >> ----- Original Message ----- >> *From:* Kirk Grier <mailto:kg… [at] kirkgrier.com> >> *To:* Ca… [at] yahoogroups.com <mailto:Ca… [at] yahoogroups.com> >> *Sent:* Monday, September 20, 2010 3:55 PM >> *Subject:* [Cal_Boats] Patching bulkhead instrument cutouts >> >> Greetings, >> >> Not sailing but boat repair how-to ... >> >> I have replaced my (2) 4.5" round Signet instruments & 3" tach and >> now have >> holes in the bulkhead between cockpit and interior to patch. I have >> a couple >> ideas, but thought I would ask the list if someone has already done >> this and >> how. The boat has fading exterior LP paint, and interior wood strip >> liner, so >> refinish is not my main concern. >> >> My two basic choices (other than screwing Starboard over the holes) >> appear to be: >> >> 1) cut a wood patch to fit the existing hole, perhaps beveling the >> edges of >> both and making the round hole square first, then glass in. >> >> 2) placing a framing structure into / across the hole, and then >> filling with >> thickened epoxy resin or the stranded reinforced body filler. >> >> Kirk >> Cal 2-34 Footloose >> Ventura, CA >> >> -- >> Kirk Grier >> kg… [at] kirkgrier.com <mailto:kgg%40kirkgrier.com> >> >> >> >> __________ Information from ESET NOD32 Antivirus, version of virus >> signature database 5474 (20100923) __________ >> >> The message was checked by ESET NOD32 Antivirus. >> >> http://www.eset.com >> >> >> >> __________ Information from ESET NOD32 Antivirus, version of virus >> signature database 5474 (20100923) __________ >> >> The message was checked by ESET NOD32 Antivirus. >> >> http://www.eset.com > > -- > > Kirk Grier > kg… [at] kirkgrier.com > > -- Kirk Grier kg… [at] kirkgrier.com