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Discussion Starter #1 (Edited)
Upgrading instruments and the old holes are far larger than the new instruments. After filling the old holes with fiberglass and drilling the new/smaller holes, I had templates made to cover the new fiberglass. What material should I use between the StarBoard, gel coat and fiberglass to made them watertight? (templates will be screwed to bulkhead)

 

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Having done this just recently with my hatches and windlass the only way to get a good seal is to mechanically attach the Starboard with screws or bolts.
Any good bedding compound or butyl will work but it will not adhere the Starboard to the gelcoat.
Sand the gelcoat surface and clean the Starboard with alcohol before applying.
 
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I think the OP said they planned to screw them on. I'd go with good butyl. You can even test it to see how it seals.
 

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I would use 4000 or 4200 sealant. butyl is to thick, the starboard is flexable and will warp when the screws are tightened with a thick sealant under it.
 

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I second the suggestion of Sudbury. It's the first sealant I've seen that will stick to Starboard without elaborate preparation of the surface.
 

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Discussion Starter #9
So Sudbury can be applied as a thin coating?

The screws that attach the displays will go through the Starboard into the bulkhead.
 

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Sudbury sealant is similar in consistency to other sealants in tubes. I'd run a good bead just inside the edge of the Starboard, screw it down, then clean up the squeeze out with paper towels and the recommended solvent. I think they suggest mineral spirits, it's on the tube. Work fast. It drys fast.
 

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I've used both butyl (from Mainsail) and 4200... its been only half a season now, and both seem to be quite waterproof. Also both are screwed in as well.

The stuff in white I used 4200, the stuff in black I used butyl.


Just an FYI, black starboard heats up and warps in the sun some, especially the thin stuff. Best to line it up and bed it in warm weather, not cold (I did mine in cold).
 
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