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1st big project, bronze thru-hull

5120 Views 37 Replies 16 Participants Last post by  Minnesail
My first big project on my little boat!

The Catalina 22 was built with a garden-hose style valve glassed directly to the hull for the sink and cockpit drain. I'm replacing it with a bronze thru-hull.

This might be mass overkill for a tiny boat that will be sailing on a tiny lake, but one of my goals with this boat is to learn how to do things The Right Way so I'll have the experience for future, larger boats.

So I've got a printout of Maine Sail's instructions, and a big pile of 1" bronze hardware:

Any tips, tricks, or advice?
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Yeah, I have a little sheet of G10 that I'm going to use for the backing plate. That stuff seems crazy durable!

So the jigsaw works for round cuts? I was thinking about that, but I'm afraid I wouldn't be able to cut a very neat circle.

The other option is a hole saw, but that means picking up a moderately expensive hole saw that I'd likely only use once or twice.

(It would also mean clearing away the rubble from the corner of my garage so I could get to my drill press, but that's another issue…)
Bi-metal hole saw. Dig out the drill press. G10 is tough stuff. I used a pulsing technique on drill press to fab several backing plates from 1/2" G10.
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