Rebed Cabin Top Hardware

The J27 has 15 fittings, two tracks and two handrails on the coachroof.  In addition there are two genoa tracks on the deck adjacent to the coachroof.  That is a lot of thru deck bolts and a lot of opportunity for leakage and wet core.  For 2009 the plan was to remove all hardware from coachroof, overdrill all holes, dig out core on small wet spots and recore on major spots and then fill with thickened epoxy, redrill and remount hardware.

The first step was to remove winches, stoppers, cleats, fairleads, cheek blocks and padeyes. Once removed each hole was drilled oversize - but not thru the lower glass layer.  The picture above shows the holes drilled and then the immediate area core removed.  The darker coloured shavings represent wetter core.

I used an allen wrench in a drill to remove core immediately surrounding each hole.  Be carefull as there is a lot of torque!  Then I vacuumed up the removed balsa and used the second allen key to pry any excess loose.

After cleaning and vacuuming.  Note the core in bottom hole is solid and dry.

Tape over holes inside to prevent epoxy mess inside boat!

Holes filled with East System thickened epoxy

Handrails and jib tracks removed and all holes filled with thickened epoxy

Nonskid applied - Interlux Interdeck.  Note the pulpit and genoa tracks removed for next project

Cabin Top Hardware 50% reinstalled and bedded.

Nearly there.  Pulipit and cabin top fittings rebedded.  Handrails & genoa rails remaining

All cabin top fittings and bow pulpit rebedded using 3M 4200 fast cure.  A bit of overkill but it has worked for me in the past.  Port and stbd genoa tracks and adjuster blocks and stbd winch remain to be installed as well as handrails which are being refinished.

All hardware and tracks installed