Stainless handrail repair

Dave! You're the PITA who ordered the wrong size bases! Is Victor taking care of you?

It was me! It was me! SOMEONE has to be that guy. The sun was in my eye. Honest it was. Maybe it was the rain. Can't remember, eyes and memory going bad.
Haven't heard from him yet probably be on my door step when I get home. Won't get back to the project until after the holiday weekend anyway. The other items are installed and fit perfectly. Guess there was only one size... fits most, you know.
Dave.

Maybe it was the margarita maker!

As to the stanchion, I'm a bit late to the party, but wanted to share a similar experience. We had a stanchion base break in the exact same way when a boat rafted to us hit it when a large wake came through the anchorage (we've gotten much larger fenders since then). Our stanchion wasn't a perfect 90 degrees, like yours, so the sleeve/base option was out. Like your boat, removing the whole rail (this was the bow) would have been a major project, at least as to reaching the bolts for at least one or two of the stanchions. We ultimately had a friend bring his welder down to the dock to reweld the base. It didn't come out perfect, and required some grinding and polishing, but it really isn't noticable if you are not looking for it. Unfortunately for us, I also had to do some fiberglass repair. All is now done, except for the gelcoat, which I'll finish when the weather cools down a bit this fall. Best of luck and have a great long weekend!

EDIT - we also bedded with the butyl tape. I had some from a big box store that we tried on a prior repair on our sailboat and it was horrible. I subsequently ordered some from Compass Marine (RC/MaineSail) and his stuff is the real deal. We used it to rebed every fitting on our sailboat, and have been using it exclusively as we work through rebedding things on the current boat (including some window frames). No leaks, easy to work with, and never hardens. the only downside is that you will find it oozing out for a few weeks after the install (particularly when it gets hot), but it is easy to remove so no big deal.

Can I get a link to find that good butyl tape? Many thanks

Not sure if HopCar carries it, but if not, you can order it here. Two rolls was enough to do our entire sailboat, and we still have most of a roll leftover. Luckily, it doesn't go bad with age. ***Buy Bed-It Butyl Tape*** Photo Gallery by Compass Marine How To at pbase.com

Thanks so much!

I haven't got the tape. I've heard that Maine Sail sells the best. I'm still a 5200 guy but I'd stock the tape if I could figure out who makes it.

GMARR that's where I got it.
Compass Marine.

I've been waiting to order some and since I close on my new to me boat tonight, I finally placed the order since some leaks are in the project list!!!!

Cool, Good luck with the repairs. You get what looks like a lifetime supply of the tape for less than 50 bucks. I haven't used it yet but others who use it rate it well.
Dave.

If there is a brand name on the tape, I'd appreciate it if you guys would let me know.
I'd like to stock it in my store.

Parks, follow the link in DHAYS post #9 . Compass Marine is the company name. May give them a call I think they make themselves.
Dave

No, compass doesn't make the stuff. I think he found a good supplier, but no idea from whom or where he gets it. There is no label on the roll. And, like I mentioned before, not all butyl tape is the same (we tried some from a big box and it wasn't even close, it actually dried out on us in less than a year).

Ok , I stand corrected I think.

Greetings, and Welcome back.
WHEW! I finally got everything together to complete the repairs to the broken handrail on the SeaNote. First I had to get access to the screws holding one of the rail stanchion bases through the headliner in the stateroom. Luckily for me it happened to be in the locker so hiding the damage will not be an issue. And this is why I chose to just repair with the rail in place instead of removing the entire rail for repairs that would be undetectable from above. All of the other stanchions are under the headliner in the master stateroom. I understand that having stanchions look dissimilar is not the ideal way to make the repair but the other options were going to be either much more difficult/impossible for me to do-or inconvenient. i.e. take a day off from work to wait for a welder to cometo the boat and weld in place the original base plate. This would still look a little different from what the original looks like. SO here is what I did.
First remove the original hardware. Easy breezy, sort of. When the boat was built the screws were broken off after the nuts were tightened. Maybe to prevent them from working loose, maybe just for conveinence. Whatever the reason breaking them off that just made normal removal impossible for me. SO I broke out the handy drill and drilled the heads off from above and drove them out.

Next clean up the white goop that was used to bed stanchions originally, mount new base.

Of course the hole pattern on the new stanchions is not the same as the originals. Why would they be. So new holes were laid out drilled and chamfered with countersink bit. I filled the old holes with Epoxy. I was surprised to note the thickness of the gel coat.


Prior to laying the Butyl tape I cleaned the surface with Alcohol. I forgot the Acetone. Then I laid the tape over the mount area. Installed the base over the tape. Prior to installing the 1/4-20 stainless machine screws I wrapped the screw head and threads down about 3/4 of an inch with the butyl tape.

The installation, as I understand from others, will take several gentle tightening’s to allow the tape to squeeze out wherever it wants to. So that is what I plan to do.

Lastly for today clean up the excess tape have a beverage. I Had to share the beverages with my dock mates Larry and MO. Cheers Mates,thanks for watching. I mean HELPING. Could not have done it without you.


Thanks to the forum members that shared input and points to ponder. Thanks to the vendors that had products available and getting them to me promptly. I am pleased with the quality of the products used and service from the vendors. If you need similar products PM me and I will be glad to share that information privately.
Dave

As someone looking to buy my opinion is that recently looking at a boat that had handrail stanchions broken is that I would much rather see different bases than broken handrails.

Greetings,
Mr. T. Looks pretty sharp! Had you considered using larger washers under the 1/4-20 nuts?

RT, Yes I did consider that and should have. My experience with fasteners on metal equipment kept fogging my thinking. I have dissassembled several things over the years that worked loose just because someone had used large washers under the appropriate size washer. That allowed the proper size washer to bend and thereby loosen the connection. That would not have been a problem here as the applied torque will be low because it is fiberglass with balsa core. Easily crushed. Yes I should have. Would not have hurt a thing here.
Thanks, Foliver that is what I think as well. This rail had to be repaired because of the location where we go up and down to the rear deck. It was a Safety hazard for sure. And when our kids sell the boat after I Die or go to a HOME I won't care what they get for it. Neither will they.
Dave

Nice job. I doubt if anybody will notice that the base is different. It certainly looks better than it did.

I think RT was suggesting you use fender washers, not stacking washers to get bigger coverage. I think 1/4" fender washers are 1-1/4" OD.

OH, Yes I looked for stainless fender washers but I was last minute Sunday shopping at Home Depot. They did not have them in stainless. Come to think I could have used carbon steel on the inside. Too late now, I Ain't about to take it apart. A couple of the fasteners are too close to the walls to get fender washer on any way I think. Could not get pictures of the one on the lower deck. Could not see it without a mirror. I had to feel my way up to those. It was so tight in there I could only use two fingers to start the nuts on the screws! Luckily could use several extensions on the rachet to tighten them up. Still was a strain to get to them.
Good suggestion RT. Thanks Parks for clarifying what was said. One track mind. When its on a track.
Dave

Toolbuddie said:

OH, Yes I looked for stainless fender washers but I was last minute Sunday shopping at Home Depot. They did not have them in stainless. Come to think I could have used carbon steel on the inside. Too late now, I Ain't about to take it apart. A couple of the fasteners are too close to the walls to get fender washer on any way I think. Could not get pictures of the one on the lower deck. Could not see it without a mirror. I had to feel my way up to those. It was so tight in there I could only use two fingers to start the nuts on the screws! Luckily could use several extensions on the rachet to tighten them up. Still was a strain to get to them.
Good suggestion RT. Thanks Parks for clarifying what was said. One track mind. When its on a track.
Dave

Click to expand...

My local Ace Hardware store has stainless steel fender washers.

@Hopcar. The name 'mortite' ring any bells? I used that in the 70's for hull/deck joints. And deck fitting attachments.

Capps, I had to look up Mortite. Sounds similar to the butyl tape. I've never used it as they don't seem to market it for marine use. They may be missing a big market. I'm a 5200 fan but I'll sell what ever people want to buy.

IIRC moretite was originally a marine product. But they have branched out into mass markets. Notice the braided rope name. It is the same (allowing for foggy brain) that I remember from years ago.

Super tacky, but never really dries up. Opposite of 5200. More like a silicone that doesnt cure hard. One thing it does not work well on is in a flexible joint. or if any swelling shrinking will occur. but to mate two hard inflexible surfaces it works great. and is removable.

At risk of getting fat shamed again

heres a great source for butyl tape. Hopcar, considering how some resellers mark this stuff up, theres plenty of upside for you even at their retail prices.

Best Materials LLC - Discount Roofing Materials, Roofing Supplies, Roofing Products, Eternabond, Fasteners, Vents, Waterproof Coatings, Safety Products

what_barnacles said:

At risk of getting fat shamed again

heres a great source for butyl tape.

Best Materials LLC - Discount Roofing Materials, Roofing Supplies, Roofing Products, Eternabond, Fasteners, Vents, Waterproof Coatings, Safety Products

Click to expand...

No shaming. Great to have a potential optional source. That said, I'd be curious to compare the quality. We bought some from a big box store a few years ago and it turned out to be junk. It had a strange texture and actually dried out somewhat. We had to re-reseal the fittings once I got the good stuff. No idea the quality of the best materials stuff but at the price it may we worth someone checking it out. With the two rolls we got we still have over half and that is after having resealed every deck fitting on our last boat with it.

I bought 1" and 2" rolls of tape months ago, still pliable and still sticky. I dont know if it will last until the next time I need to rebed, but at that price I dont really care.