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Old 07-28-2013
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Re: The final solution - what I came up with regarding auxiliary propulsion (pic heav

The projects that were the most difficult were often the most easily overlooked ones, and a lot of the "pretty" stuff (like the bracket) weren't all that difficult at all.

Take the toe rail for example, that was very difficult. Very few oohs and ahs about that upon completion, as it was just a simple "off the rack" 34' (x2) length of toe rail. Think about it however, how exactly do you install it and bed it with butyl?

1- Start with a filled and faired hull to deck joint (a big project in and of itself)
2- Place forward portion of the rail where it's to go, place wife on shoddy ladder 20' out and 10' feet up from aft of boat to hold the straight length of rail as you drill the first hole and temp. drop first fastener into the hole to hold the rail on.
3- Have wife balance the rail on the ladder (careful there), move ladder in a bit, then climb back up and pull the rail in for the next hole and fastener to be repeated as the first.
4- Repeat, over and over until the last fastener is in (gets much harder as you proceed, as the rail gets more and more "bent on" and the pressure to bend it on needs to greatly increase. The fact that the rail was 4' longer than the boat greatly helped in achieving the leverage needed to bend it on). We couldn't have bent it on had we cut it to the proper length beforehand.
5- Now the rail is on, unbedded and with drill shavings piled up underneath it.
6- Next, remove temporary short fasteners holding the rail on in favor of long fasteners, one by one.
7- Realize at this point that the long fasteners - which are needed to give the ability to lift the rail high enough to clean the shavings and apply the butyl - won't fit in many areas because they are so close to the edge.
8- Custom fit each fastener to work. Some need trimming, some need a slight bend applied to them. There are many. So many..
9- Remove certain fasteners that won't facilitate lifting the rail (better not remove too many though).
10- Carefully and gently pry/lift rail as high as possible without removing it. We were able to lift about 3".
11- Clean shavings, do any spot prep that became necessary.
12- Apply butyl. Do a long unbroken line the entire length of the rail, inside and out, and do a circle around each and every fastener.
13- Gently tap rail back down the entire length.
14- Send wife inside to crank down as you hold fast up top.
15- Test for leaks, leave to settle for a couple of days and give the butyl time to ooze.
16- Give everything a final crankdown and wait again for ooze. Trim ooze.
17 - Trim off overhanging aft part of toe rail to proper length.
18- Smack head and wonder why you didn't just build a bulwark out of epoxy to begin with.

The rail was incredibly difficult, one of the most difficult, and once installed only noticeable in it's beauty to those who have any idea what it takes to install something like that.

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