Removing engine-panel "alcove" on a 25D

[Joe Myerson]

Honestly, folks, this a fall project. Crème Brulée launches this week at last.

But while trying to solve the Great Gooseneck Conundrum, I ordered a beautifully made Lexan cover for my 1GM instrument panel from a great little company called Seaworthy Goods. The cover is a perfect fit, designed specifically for the old-style instrument panel.

However, it looks like the best way to install it would be to remove the white plastic box, or alcove, that holds the panel recessed into the aft bulkhead of the cockpit. This box is attached to the bulkhead with self-tapping screws and ample quantities of a white, flexible sealant or bedding compound.

Does anyone know how difficult it would be to remove this stuff? Please, Oh Sea Gods, let it NOT be 5200!

--Joe

[Sea Hunt Video]

Joe:

I have removed mine a couple of times. The "white stuff" was easy to cut with a knife. The panel came off without difficulty. I did not add any Boatlife caulk the first couple of times. The last time I did, at the recommendation of the diesel mechanic (the best ).

I am a rookie but I doubt it is 5200 stuff, otherwise you would not need to 8-10 screws.

[Joe Myerson]

Thanks, Robert. It didn't look like 5200 to me. My boat-repair guy swears by BoatLife's products. The boat was hauled from my yard this morning, and I should be sailing by mid-week.

--Joe

[Steve Darwin]

Joe:
Last year I removed the instrument panel ("alcove") to access and replace the tack vents. The panel was bedded in a soft white calking that was easy to remove. Several of the screw holes had broken out of the cockpit bulkhead so I backed up the edge of the hole with some strips of wood glued in place so the screws would have something to grab, and I reduce the size of the hole by about a half-inch to better fit the panel. To seal the panel edges, I used the self-stick weather-stripping (compressible vinyl foam) that comes in rolls.

[trapper]

Hi Joe,

Saga is hull 180 and it is sitting there with nicks and mars from time and from my failed attempts to remove it! Don't know what it is -- it will have to wait until the full deck and cockpit refit-- due soon!

[Russell]

Hi Joe,

Saga is hull 180 and it is sitting there with nicks and mars from time and from my failed attempts to remove it! Don't know what it is -- it will have to wait until the full deck and cockpit refit-- due soon!

For what its worth, most CD origonal bedding seems to be either Sikaflex or Silicone, both of which are pretty easy to remove. If you had that much trouble trying to remove it, I bet it was rebedded by a previous owner with either 5200 or 4200. Both of which (and any bedding compound) will be much easier to remove with a heat gun. Just be careful with your heat gun around varnished or painted surfaces, the original gelcoat can take a lot more though.

[shinchman]

I removed a similar instrument panel from my cape dory 27 (a year after my mechanic did it). As with Saga, the engine panel is mounted in a fiberglass "alcove" -- which was destroyed last year.

I have to repair sporadic short on the start button (solenoid?) and switch out the ammeter. That gives me the winter to either find a replacement alcove (the white box in the picture) or make one.

Has anyone created a mold, or found a source for a replacement "alcove" (is that what they are really called - would help for searching), or come up with a better instrument panel mounting idea?

BTW, you will notice its a Universal panel, which is cause I got lucky and found a CD-27 with an up-powered 16 hp 2 cylinder M-20 Universal Diesel.

[Jim Walsh]

You have damaged sections but the "alcove" isn't destroyed. I'd use the existing sections as templates and use fiberglass to repair the damage. Sanded and painted, the damaged sections would be nearly invisible. Barring any attemp at fiberglass repair I'd use the existing structure as a template for a replacement constructed of marine plywood. I'd then use Fiberglas cloth and west epoxy to encapsulate the marine plywood and paint it with a one part epoxy paint. It's a relatively straightfoerward job that even I would attempt.

[moctrams]

I replaced mine from these folks in Southern Maryland.

http://ssicustomplastics.com/products/i ... uct_id=191
http://ssicustomplastics.com/products/i ... 28x228.jpg