Tool to remove core to properly mount deck hardware - SailNet Community

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Old 03-12-2012
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Tool to remove core to properly mount deck hardware

Hi, best practice when mounting/bedding deck hardware on a cored deck is to remove some of the core surrounding the holes to protect the remaining core from water intrusion.

For big holes, traditional tools can perform this job. For tiny holes, like one for a single fastener, a person can apparently use a bent nail in a drill.

For medium sized holes, like for cockpit and deck drains, I found that I could not get regular tools in there, and a bent nail would just jump around as it made and lost contact with the core. Maybe a sturdy hand and drill press guide or attachment could make this work. But after trying a few grinding bits for my drill and Fein MM, I tried a Kutzall Extreme - Rotor Saw Burrs (RSX-114F) in my drill. It was easier to control, worked fast, and appears to me to be an ideal and inexpensive solution for this task. I'm not sure where they are sold, but I got mine on eBay:

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Old 03-12-2012
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Re: Tool to remove core to properly mount deck hardware

Stick an allen wrench in your drill (short side down).
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Old 03-12-2012
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Re: Tool to remove core to properly mount deck hardware

I've got a couple of 1/8" allen wrenches that I've cut the short end down a bit for different sized holes. They work OK but if they get hung up it twists them pretty easily. Looks like those burrs would require a pretty large hole to get into, but if that flat one happened to be the same size as the hole it would work great.
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Old 03-13-2012
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Re: Tool to remove core to properly mount deck hardware

I use a dremel router bit in a flex drive. The bit below is 1/4" diameter and bit #115 is 5/16" diameter. They work well - the 1/4" one shown fits in most hardware holes. This tip originally came from Mainesail.
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Old 04-10-2012
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Re: Tool to remove core to properly mount deck hardware

I have this bit and I'm sure it would work great...if the core was thick enough. It's only about 1/4 or so in the area I need to grind out. I could try the allen wrench but that seems kind of crude.
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Re: Tool to remove core to properly mount deck hardware

An Allen wrench works. Or you can use a bent nail. It doesn't have to be neat as the epoxy will cover it.
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Old 05-29-2012
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Re: Tool to remove core to properly mount deck hardware

I have used different burs - the down side to a bur is that most of the time it was too big for the hole and I ended up with a large hole on the top side. Tried the bent nail and sort of worked but bounced a bit.

The last tool has been a series of about 1/8 inch Allen Wrenches with the short ends ground down - I have several different lengths - the smallest or shortest is small enough to rotate freely in the base hole. Then I beat out the core (Balsa in my case) then switch to a slightly longer Allen Wrench and repeat a few times until I get the core enlarged to the size I want - - the secret with the Allen Wrenches is not to use too long a short side - when the short side is too long or you get too greedy and in a hurry the bit will bounce around and get bent - - on the good side the 1/8 inch Allen Wrenches don't cost much if you buy them at an industrial supply house. Seems I might have paid maybe $ 1.50 for 6 wrenches.
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