This thread is related to the broken screw thread, but really, it's a separate topic about rebedding, so I'm starting a new one. Hope that's OK!
As I mentioned in the other thread, we're removing and rebedding our handrails. I was surprised to find they are screwed into the deck with self-tapping screws.
Now, I'm ALL FOR sealing the core from deck hardware. And I hate that the hand rails are just screwed in place. However, there are roughly 40 - 50 screw holes, and there is no way to through-bolt them without serious interior damage/modifications that I'm just not going to do. Each "foot" of the handrail has two screws, and the handrails are very long.
The cabin top and the handrails are curved, so once off, they don't just "line up" with the original holes. So pressure will have to be applied to get them to line up.
So is it realistic to drill out the holes (outer skin and core only, not the inner skin since there's no hole there), and fill with epoxy, then redrill holes in the epoxy for self-tapping screws? Would this even work? How would I make sure the new holes lines up? And can one just screw into epoxy without it cracking or something? Why are we here?
Or should I just clean it all up, and rebed with polysulfide, knowing that it just needs to be redone every 5 years (it probably hasn't been done once in the last 26)?
Thanks as always!