Mounting Hardware on 25D cabintop

[frankfurder]

I am planning to route mainsail halyard and reefing lines to the cockpit on my 25D, I understand that there is a gap between the deck/balsa core and headliner in the cabin. Have searched this site and others for best way to reinforce this gap with epoxy before drilling holes for mounting organizer, stops and winch. Any suggestions?

I would just plan to use unthickened epoxy to seal the gap, but am not sure that it wont just fill a bigger area than necessary.

Other suggestions are to drill thru the deck/core but not the headliner before using epoxy to wet out the core, then fill hole with thickened epoxy and drill mounting holes all the way thru, using backing plate/washers inside of course.

Thanks!

[Steve Laume]

I added an eye at the bow for my jack lines. I wanted this to be very strong for obvious reasons. I drilled through the deck and started to pour thickened epoxy into the gap. Well I poured a lot of epoxy in there and never saw signs of it filling the gap. At that point I figured I had created a thick enough area of the liner to go with a backing plate and just bolt the thing in. Since this would only ever be a shear load, I have complete confidence in the installation.

Cape Dory did not fill the gap when they originally installed the cabin top winches. Again, this is a shear load so there is very little stress on the liner. The same would be true for you deck leads. The turn from the mast to the deck would have some tension loads but a large backing plate would probably handle that as well.

You don't really need washers if you are using aluminum backing plates. The fasteners for the winches are tapped into the backing plates so there are not even any nuts. This makes for a very clean and smooth installation.

You could cut out an access hole and then just bolt to the deck with a wood cover much like the mast access.

Whatever you decide to do just make sure to fill the core, Steve.

[Sea Hunt Video]

Frank:

I have been "planning" this same project on S/V Bali Ha'i for the past 2+ years. I keep chickening out when it comes to drilling holes. I was told by someone (I think on this board) that there is a significant gap between the deck and the liner. Enough of a gap that you can supposedly attach nuts to bolts in between the liner and deck. This does not seem right to me but I have not yet gotten the nerve to start drilling.

PLEASE KEEP US UPDATED ON YOUR STEPS

[Bob Ohler]

Many years ago, I did this exact project on CD25D #2. I had to stop and think about how I did it. It just came back to me.

Don't try to fill gap between the deck and the headliner. You'll go broke buying epoxy. And you will have no idea if you have filled the gap.
I added winches for both halyards. The winches were on the cabin top on either side of the companionway. If I had it to do again, I believe I would go with just 1 winch and add a rope clutch in front on the winch. I would use blocks at the mast to route the halyards to the stopper and winch.
Now for the good part. I took a hole saw and cut a hole in the headliner for an aluminum backing plate of suitable size for the winch(es) I was installing. I also used the same hole saw to make my aluminum backing plates. It worked!
Now, you MUST bed the bolts going thru the cabin top!!! In addition, you need to seal the interior of the holes that you will drill going through the deck. If you don't, you will be leaving a path for water infiltration into your fiberglass. I strongly recommend thickened epoxy to seal the fiberglass deck holes. (West System Six 10.) In addition, I would bed the bolts with butyl tape. Search Maine Sail and his EXCELLENT tutorial on the doing this.
To clean up the appearance of the holes in the headliner made by the hole saw, I turned 2 - teak "plugs" from 3/4" material. (It doesn't have to be teak, but it looks professional if you do.) On each of the plugs, I cut a shoulder into the edge of the plug while the plug was still in the lathe. If you don't have a lathe, find a friend who does.
I gotta tell ya, the halyards at the cockpit were nice when sailing solo. Take my suggestions above, plan your work, review your plan, and make it a great addition to your CD25D!

[jbenagh]

There is a way to epoxy the hole that I have used. Drill a hole in the top only. Take a piece of open cell foam (size determined after you read below) and soak it in epoxy then squish it through the hole. This epoxy could be 5 minute epoxy. Take care to get it kind of evenly spaced around the hole. Allow to cure. Now drill an oversize hole thought the top and the hardened foam and fill with thickened, good-quality epoxy all the way to the top. When this cures, drill the clearance hole for the bolt all the way through the top, the cured epoxy and the liner.

Jeff

[Sea Hunt Video]

Frank:

If you could post photos as you progress in the project that would be helpful.

Thanks

[Steve Laume]

To clean up the appearance of the holes in the headliner made by the hole saw, I turned 2 - teak "plugs" from 3/4" material. (It doesn't have to be teak, but it looks professional if you do.) On each of the plugs, I cut a shoulder into the edge of the plug while the plug was still in the lathe. If you don't have a lathe, find a friend who does.

If you go this route, you don't need a lathe to make the plugs. A band saw or jig saw and a router will do the same job. Cut out a disk and then run a round over bit on one side and a rabbit on the other.

I like the epoxy saturated foam idea. Not sure where I will use it but will file away the idea in my head, Steve.

[Bob Ohler]

Jeff, I like that idea!