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 Catalina/Capri 25/250 Sailor's Forums
 General Sailing Forum
 Covering Screw Holes		  New Topic  Topic Locked
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aeckhart
Master Marine Consultant

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USA
1709 Posts
Initially Posted - 04/15/2005 :  12:14:53  Show Profile  Visit aeckhart's Homepage
I have been replacing old hardware and adding new to my boom this year and found that I had accumulated a lot of unsightly screw holes. Looking through some of the mounds of reference material I have stashed away, I came up with this simple fix - cut off a stainless screw the same size as the hole and screw it in. I cut all but two threads on each screw with a Dremmel Tool cutting wheel. The result is far more appealing than having all those screw holes everywhere.

You may not have to cut the screws off, however, with an in-boom outhaul system, I thought it best to keep internal obstructions and potential hang-ups to a minimum.

By the way, if your looking for a great all-purpose tool for boat maintenance and repair, it's the Dremmel Tool. It cuts stainless steel, shapes, polishes, grinds, etc., and when used with wood-cutting bits, is great for cutting holes in bulkheads without scratching the surrounding area and in tight spaces.

Thought you'd like to know.

Al
GALLIVANT #5801
Al Eckhart
GALLIVANT #5801
'88TR
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Arlyn Stewart
Master Marine Consultant

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USA
2980 Posts
Response Posted - 04/15/2005 :  13:03:45  Show Profile  Visit Arlyn Stewart's Homepage
Al, I'd think that aluminum pop rivets would also be a reasonable way to fill non-used holes.

I agree with the dremmel or a suitable rotary tool. Just this week, the heater hose fitting coming off the thermostat manifold (a rather involved manifold Ying to both heads) on my work truck broke off when I needed to bypass the heater core until it can be repaired. Figuring I was in deep doo doo, there was nothing to lose by trying to clear the hole, which unfortunately wasn't easy to access. Noting the softness of the broken fitting, I used a rotary tool with a burring cutter and was surprized at the ability to clear the hole of the pewter down to the pipe threads after cycles of grinding and inspecting with a mechanics mirror.

Getting the pewter out of the threads required a little more effort and I wished for a small wire brush for the rotary tool which I thought might have cleared the threads. After some initial and failing efforts to pik it out, a rough effort produced a tap by using a cutoff grinder and cutting slots in the end of a pipe nipple. This proved to work well cutting the pewter from the threads.

When a brass plug was safely in the manifold... a great sigh of relief could be heard for a block.
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aeckhart
Master Marine Consultant

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USA
1709 Posts
Response Posted - 04/15/2005 :  14:43:58  Show Profile  Visit aeckhart's Homepage
Arlyn

I had thought of using ss or aluminum pop rivets but wasn't sure how much of the rivet extended inside the boom. I'm a little sensative to my internal outhaul catching on long screws, rivets, etc..

Al
GALLIVANT #5801
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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.