January 4, 2018
With various known hardware locations on deck, I chose to bore out and prepare these holes now, looking to streamline the hardware reinstallation later. In addition, there were several now-obsolete fastener locations that required filling before primer and paint.
Starting on the coachroof, I bored out all the handrail fastener holes with a 5/8″ bit, reaming out the core around the fastener locations. The existing spacing seemed to work with the published dimensions of the new teak rails I planned to install. I also bored out all the screw holes from the sea hood, and a few other fastener locations where I knew the original hardware would be reinstalled. In other areas, I reamed out the tops of fastener holes that would be abandoned going forward. With a small grinder, I ground out a few stress cracks that emanated from some of the fastener holes so that I could fill and repair these minor areas. Afterwards, I vacuumed out the holes and drill spoils, and solvent-washed the entire coachroof.
Next, I filled all the 5/8″ fastener plugs with a strengthened and thickened epoxy mixture, pushing out air and packing the holes full. (I’d taped over the holes from inside where needed.) With that complete, I skim-coated the coachroof with fairing compound, sticking mainly to the nonskid areas to fill what remained of the nonskid pattern that I’d sanded earlier. I also filled obsolete screw holes, as well as the various cracks I’d ground out.
With the work on the coachroof done for now, I repeated the basic process on the sidedecks and foredeck, though there were far fewer holes to deal with here. The winch islands required some additional work, including grinding out some stress cracking and preparing myriad holes for filling, as the hardware being installed here would be completely different than what I removed.
After cleaning up, I filled the fastener holes as needed, then skim-coated the old nonskid pattern with more fairing compound.
In and around the cockpit, there was just a bit more fairing work to do on the poop deck and icebox repairs, taking care of some lingering low spots.
Total time billed on this job today: 5.25 hours
0600 Weather Observation: 10°, cloudy and light snow. Forecast for the day: Heavy snow with blizzard conditions in the afternoon, 20s.