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· Iroquois MkII
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Discussion Starter · #1 ·
Hi everyone,

I have an Aqual Signal Waterproof Plug Connector that I plan to use for the mast light connections.

The problem is that the screws to mount it are really tiny, 4 of them, surrounding a larger hole that the wires pass through. There's a rubber gasket on the bottom of the plug that gets pressed against the deck to keep water out.

How do I go about sealing this so water doesn't intrude into the core? The big wire holes, I can route out the core between the skins around the hole and fill with thickened epoxy. I'll chamfer the edge of the hole as well, although it seems pointless since the plug won't be putting any pressure around the hole to squeeze any sealant into the chamfered area.

The 4 tiny screws are a bigger problem, do I drill out & fill with epoxy, and then drill small pilot holes halfway thru, chamfer & just screw into the epoxy itself?

Finally what's a good sealant for this? Presumably the sealant goes between rubber gasket & tiny screws. Would I load up the hole the wires go through with sealant as well?

Thanks!
 

· Iroquois MkII
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241 Posts
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Discussion Starter · #5 ·
So I've got everything drilled out, routed out, filled with epoxy, ready for re-drilling and actually attaching the plug.

I emailed Aqua-Signal on how they would do it, and got this reply:

"I would use a sealant like a 3M 5200 for the screw holes only. This is only to protect your deck from water intrusion/absorption."

Well I'm loath to use 5200 anywhere on my boat, that stuff is horrendous. I'm not happy at relying on that rubber gasket though - it would effectively prevent water from migrating through the main wire hole, but what about wicking down the screws themselves? If I through-bolt, that water would get into the cabin, and if I just screw in, I don't know if I'll put enough pressure on the gasket. Or do you think through-bolting would press rubber against the screw enough to prevent water entry?
 
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