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Catalina/Capri 25/250 Sailor's Forums

General Sailing Forum

New instruments - old holes

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OJ
Master Marine Consultant

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USA
4382 Posts

Initially Posted - 05/30/2015 : 17:25:47

Removed old instruments in preparation for installing new . . . and the old holes are a considerably larger than the new instruments (even slightly larger than the new faceplates)

So I basically need to fill in the old holes and re-drill smaller ones. The bulkhead is roughly 3/4" thick.

I plan to plug the holes with layers of fiberglass and top off with gel coat.

Anyone have other suggestions, experience?

1989 C25 TR/WK, #5822
1973 McVay Minuet 19
1975 Jester 12
1981 C25 SR/SK, #2428
1981 C22 SR/SK,
Tanzer 16
Sunfish

"There is nothing, absolutely nothing half so much worth doing as simply messing about in boats." Kenneth Grahame

Edited by - OJ on 05/30/2015 17:31:17

Steve Milby
Past Commodore

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USA
5909 Posts

Response Posted - 05/30/2015 : 17:54:38

You could cover all the old holes with a piece of starboard, and then attach the new instruments to the starboard.

Steve Milby J/24 "Captiva Wind"
previously C&C 35, Cal 25, C25 TR/FK, C22
Past Commodore

islander
Master Marine Consultant

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USA
4029 Posts

Response Posted - 05/31/2015 : 11:45:16

quote:
You could cover all the old holes with a piece of starboard, and then attach the new instruments to the starboard.

I agree with Steve, Much simpler and is what most would do. Unless your an expert with fiberglass and matching colors the fiberglass repair would probably be very noticeable and in an area that is frequently viewed.

Scott-"IMPULSE"87'C25/SR/WK/Din.#5688
Sailing out of Glen Cove,L.I Sound

Stinkpotter
Master Marine Consultant

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Djibouti
9089 Posts

Response Posted - 05/31/2015 : 12:02:03

quote:
Originally posted by Steve Milby

You could cover all the old holes with a piece of starboard...

...or teak. I, too, would not try to fill and then re-cut. (I'd probably use Starboard.)

Dave Bristle
Association "Port Captain" for Mystic/Stonington CT
PO of 1985 C-25 SR/FK #5032 Passage before going over to the Dark Side (2007-2025); now boatless for the first time since 1970 (on a Sunfish).

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 05/31/2015 : 14:03:08

Thanks guys, project pix to follow . . .

shnool
Former Capri-25 Tech Editor

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USA
1032 Posts

Response Posted - 05/31/2015 : 19:07:24

Pictures worth a thousand...

C&C 32 Smith Mountain Lake Virginia

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 06/08/2015 : 17:52:53

10 layers of fiberglass so far and have filled only 2/3 of the depth of the holes

Ordered 18 and 24 oz. roving weave from JD.

All this only to drill new (smaller) holes

Found a sign maker with an XY cutter that is going to make templates (at 115%) that will match the exact shape of the instrument bezels

Pix to follow.

Edited by - OJ on 06/09/2015 16:48:48

redeye
Master Marine Consultant

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3477 Posts

Response Posted - 06/10/2015 : 04:03:46

I filled my deadlight with the thickened gflex, still gotta gelcoat over it. Done a lot of glass work but not much gelcoat.

maybe your could put a waxpaper and board over it and leave an opening at the top and pour it in to fill it.

West Systems G/Flex Thickened Epoxy Adhesive

just an idea, rather than laying up all that glass.

Ray in Atlanta, Ga.
"Lee Key" '84 Catalina 25
Standard Rig / Fin Keel

Edited by - redeye on 06/10/2015 04:05:00

dasreboot
Admiral

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804 Posts

Response Posted - 06/10/2015 : 04:56:16

I changed my cheoy lee 36 from large windows to small ports. plywood on the inside, layed in alot of roving and epoxy. covered with release fabric and plastic and sucked it down with a shop vac. (put a hole in the hose so it gets some air to cool the motor). then came the fairing and painting. A LOT of work. Not sure I would do it again.

Todd Lewis
Eowyn 87 TR/WK C25 #5656
ARWEN 84 TR/SK C25 #4031
www.mainsailsailingschool.com

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 06/10/2015 : 10:44:32

quote:
Originally posted by dasreboot

. . . A LOT of work. Not sure I would do it again . . .

I'm approaching that threshold

islander
Master Marine Consultant

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USA
4029 Posts

Response Posted - 06/10/2015 : 16:03:29

quote:
10 layers of fiberglass so far and have filled only 2/3 of the depth of the holes

That's why there is plywood sandwiched between two skins of fiberglass. I'm really surprised that you took this route for the repair. I hope your really, really good at matching gelcoat because that is what you will constantly see in that location.

Scott-"IMPULSE"87'C25/SR/WK/Din.#5688
Sailing out of Glen Cove,L.I Sound

britinusa
Web Editor

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USA
5404 Posts

Response Posted - 06/10/2015 : 16:20:36

Router really nice clean edges around the old holes and then gel coat in an obviously different color (Grey, Black, Blue, whatever) and put your new holes in that. It might look really sharp.

Paul

Joint Decision. (Sold)
PO C250WB 2005 Sail # 841.

Moved up to C34 Eximius

Updated August 2015

NautiC25
Admiral

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USA
957 Posts

Response Posted - 06/11/2015 : 14:08:32

I'm taking the easy way out. Installing 6" marine speakers, then mounting new mast-mounted gauges later. I'm tired of blasting the cabin speakers just so I can hear it out in the cockpit.

1989 C-25 TR/WK #5894
Miss Behavin'
Sittin' in LCYC on Canyon Lake, Texas

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 06/16/2015 : 18:54:12

Gel coat is stupidly expensive - so I am going the StarBoard route. Sample template I had made to cover old/large instrument holes:

24 ounce roving weave filled the holes much faster:

Edited by - OJ on 06/16/2015 19:41:17

Stinkpotter
Master Marine Consultant

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Djibouti
9089 Posts

Response Posted - 06/16/2015 : 20:01:42

Coremat might have been even faster--about 1/6" thick. Defender sells it by the yard--you might be able to get some scrap from a fiberglass fabricator.

The Starboard plate looks good--the nice thing is it works like hard soap, with ordinary wood tools.

Edited by - Stinkpotter on 06/16/2015 20:02:33

redeye
Master Marine Consultant

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3477 Posts

Response Posted - 06/17/2015 : 07:24:18

Or you might make a mold with the new hole in the middle, essentially a doughnut or collar, to fill the gap.. that way you could lay it up laying flat before inserting.

Might use Kitty hair for the mold.

Anyhoo OJ that looks great.. Your gonna have the strongest mounts in the industry...

Ray in Atlanta, Ga.
"Lee Key" '84 Catalina 25
Standard Rig / Fin Keel

Edited by - redeye on 06/17/2015 07:26:00

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 06/17/2015 : 14:24:19

quote:
Originally posted by Stinkpotter

Coremat might have been even faster--about 1/6" thick. Defender sells it by the yard--you might be able to get some scrap from a fiberglass fabricator.

The Starboard plate looks good--the nice thing is it works like hard soap, with ordinary wood tools.

Yeah, I let the store manager at WM initially talk me into what he had on the shelf - stupid me!

Picked up one more sample template today - should do the trick - pix to follow.

Edited by - OJ on 06/17/2015 14:27:02

glivs
Admiral

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USA
836 Posts

Response Posted - 07/08/2015 : 17:16:00

Just curious how your project turned out...

Gerry Livingston, Malletts Bay, VT
"Great Escape" 1989 C-25 SR/WK #5972

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 07/10/2016 : 15:01:32

Responding to glivs question a year and two days later

Thanks for the above input!

Project summary:

Practicing to get the correct sizes:

Holes made by previous owner(s) were not the same size:

For filling old (oversized) holes:

After about 10 layers:

Re-drill 2 old holes, 1 new:

Thickness of bulkhead:

Coating edges with epoxy:

Bezels I had made to cover old, oversized holes:

Making sure bezel doesn't shift while drilling each hole:

Bezels ready to accept displays:

Speed display installed:

Thru-deck for wind wane. Soldering 22 AWG wires into pots + heat shrink = TEDIOUS

Raymarine makes very high quality products:

Edited by - OJ on 07/10/2016 15:23:59

Sailynn
Navigator

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USA
178 Posts

Response Posted - 07/24/2016 : 00:27:39

Looks great. Thanks for the pictures too.

Lynn Buchanan
1988 C25 SR/WK #5777
Sailynn
Nevada City, CA

Tomas Kruska
Admiral

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Czech Republic
522 Posts

Response Posted - 07/26/2016 : 01:56:46

OJ, really nice clean work!!

Btw. why you haven't bought that tri-data display instead of two separate speed/depth displays? Less holes and maybe a little cheaper.
Or get i70 series display and have all the data in one unit :-)

Dalpol Phobos 21, 2013, Sole Mio, hull #27, current adventures - We sail Phobos 21

PO of Catalina C25, 1978, High Anxiety, hull #701, SR, FK, L-dinette, inboard diesel Volvo Penta MD2010C w/saildrive - more info

Edited by - Tomas Kruska on 07/26/2016 06:43:47

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 07/26/2016 : 09:27:34

quote:
Originally posted by Tomas Kruska

OJ, really nice clean work!!

Btw. why you haven't bought that tri-data display instead of two separate speed/depth displays? Less holes and maybe a little cheaper.
Or get i70 series display and have all the data in one unit :-)

Hi Tomas and thanks for the compliment. I considered the tri-data display but drilling a third hole required less skill!

islander
Master Marine Consultant

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USA
4029 Posts

Response Posted - 07/26/2016 : 17:22:39

Why have one gauge when you can have three! The more the better. Ever look at the dash display in a 747? It's a cool factor. The only thing that could make it better would be if they were analog with vibrating needles!

Scott-"IMPULSE"87'C25/SR/WK/Din.#5688
Sailing out of Glen Cove,L.I Sound

OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 07/26/2016 : 17:58:10

quote:
Originally posted by islander

Why have one gauge when you can have three! The more the better. Ever look at the dash display in a 747? It's a cool factor. The only thing that could make it better would be if they were analog with vibrating needles!

glivs
Admiral

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USA
836 Posts

Response Posted - 07/27/2016 : 18:25:50

Well done!

Gerry Livingston, Malletts Bay, VT
"Great Escape" 1989 C-25 SR/WK #5972

Akenumber
Navigator

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USA
247 Posts

Response Posted - 08/21/2016 : 12:34:57

Yes very nice. It killed me just to turn an old 4in hole into a 5 x 7 for a chartplotter.

Ken
San Diego
84 C25 SR/FK 4116
The KRAKEN

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