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Cover a big hole?

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mday
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197 Posts

Initially Posted - 02/15/2006 : 16:12:10

I have a dead instrument in my bulkhead that has a 3.5" circular hole I need to plug up when I remove it. Has anyone seen some nice off the shelf products designed for this?

Thanks, Max

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OLarryR
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3466 Posts

Response Posted - 02/15/2006 : 16:31:39

I just dealing with same issue. I have a SR Mariner Analog Depthfinder which does not work. The hole is approximately 4" - 4 1/8" in diameter. I decided to replace it with a Humminbird Matrix 17 Fishfinder with a swingarm mounted just inside the companionway. I am still working on it but fishfinder is up and running.

Anyway...what to do about the large holes. My advice is to scour the West marine store for something that may fit and if it doesn't, at least it is easy enough to return it if you have a store in your area. Look in the vent cover areas. Nicro and Beckson make vent covers with a plastic flange of about 1/2". I do not remember the exact sizes but they are in the 3" - 4" circumference size. The only thing is you have to then deal with what to do with the screw holes in the plastic flange of the vent cover. You could use the screws to mount the vent cover but then that involves addl holes into your bulkhead. You could possibly just ignore the screw holes and glue the cover against the bulkhead.

In my case, I decided not to go that route. I bought a Craftsman Scroll saw to cut out a circle out of 1/2" Starboard (Marine Polymer) matl. I cut a 1" larger circle to provide a lip, beveled the edge using a router bit and then drilled 6 holes along the inside circle which will fit thru the original hole in the bulkhead. My plan is to then mount a polymer board inside the cabin secured mainly by the bolts from the circle mounted outside the cabin. The polymer board on the inside part of the cabin will also serve to mount the RAM Swing Arm. All the parts are ready for install and I will probably do it by this weekend. I will be taking photos and putting it on my website.

Instead of a vent cover or using a scroll saw, you could also consider using a circle cutter that fits a power drill. That was what was probably used to make the original hole. Just a question if you can find one large enough.

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frog0911
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1349 Posts

Response Posted - 02/15/2006 : 22:47:52

At the Homey Depot store you can purchase two 4&3/4" aluminum plates that are designed to cover soffett light boxes, put one on the inside and one outside with some lifeseal then pull together with some stainless bolts/nuts and it is done. Very cheap fix also. The plates appear to be powder coated and are very thin so they won't stick out to catch anything.

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mday
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Response Posted - 02/20/2006 : 00:02:10

Jerry,

Methinks you've been spending way to much time at the "Homey Depot"! As a temporary cover, some duct tape would be much simpler. Some folks can do more with duct tape that Arlyn can do with bungees.

I like Larry's idea of cutting some "rounds" to fill the hole, since I have the (large) hole saw for the original install. I could probably shape something like the original instrument .... maybe with some clever message about the short lifetime of Raymarine Autopilots.

This hole is for my dead Autopilot control head. As you know, we've had a few good reviews of the Simrad unit, but I haven't taken the plunge yet .... did you? Even so, it's self contained and I'll need to fill the hole until some other (no doubt expensive) electronic gear comes along to put there.

Max

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frog0911
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1349 Posts

Response Posted - 02/20/2006 : 06:39:17

Have not taken the plunge on the autopilot yet. Still working on the shore power and additional battery install plus some new storage additions.
You might be correct on Homey Depot. You would think the employees would klnow me by now, but the 2nd mate usually goes with me and she gets all the welcomes and dog bones.

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OLarryR
Master Marine Consultant

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3466 Posts

Response Posted - 02/20/2006 : 07:27:39

Hole plugged - Take a look - Website updated with Fishfinder details. But...forgot to take photos and write details of the transducer install. I used someone else's suggestion and took a glob of wax off of a topilet wax ring, smooshed into the rear of the VBerth area and shoved the transducer into it. Signal picks up fine and transducer seems to be snug in the wax.

Anyway, I think the circle came out pretty good for being handmade. I liked making the circle rather than buy the vent cover because the vent cover has the outer diameter holes that would if used mean addl holes into the bulkhead or if not used, then only sealant would hold the cover on. But this is an option and the circle is a perfect circle. Also, not sure if it was West Marine or Boaters World but the Beckson Vent Cover also has an option for inserting a small bag/pocket that fit the cover. One can unscrew the cover from the circular flange, insert their keys, etc in the bag and then screw the vent cover back on.

Anyway - two options for you and...making your own circle has the addl benefit that you now have a good excuse to go out and buy a Scroll Saw ! Sears has about 3 or 4 on display.

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dlucier
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Virgin Islands (United Kingdom)
7583 Posts

Response Posted - 02/20/2006 : 12:19:23

Max,

A couple of our more creative members came up with rather unique solutions for obsolete instrument holes.

This is what Doug did on Wind Lass.

"The previous owner had left me with a cheap plywood patch over an old compass hole. Port side of the aft cabin bulkhead. Here is what I did. Purchasing a deck hatch/port for 10 dollars I installed it into the hole. I used a clear port so it would look similar to a portlight. I must say it was a vast inprovment over the old plywood patch. A few months went by and some one gave us a stained glass sun catcher. My first thought was Ill bet this will fit into the old port and look quite nice. I removed the chain and hanging loop and here is a picture of how it ended up."

And this is what Richard did on Sanity,

"It used to be a knotmeter which never worked. With a very bulky backside with many sharp, jagged points, it liked to gouge out large chunks from my skull when I used the sink. So I struck back one day! I removed it and used a hack-saw to cut off the backside about 1" from the glass. After removing all the "innerds", I reinstalled it back in the hole in the bulkhead. On the inside, a router table was used to make the trim piece from some scrap teak. If I did it again, I would glue the trim piece on the inside, instead of using screws."

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mday
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Response Posted - 02/20/2006 : 13:50:30

Larry and Don,

Thanks for the good info. Very nice work in both!

Max

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OLarryR
Master Marine Consultant

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USA
3466 Posts

Response Posted - 02/20/2006 : 20:44:04

Don,

That suncatcher is great ! Best use of a vacant hole yet !

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