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Repairing a Console to Flush Mount
I was lucky enough to score some "new to me" electronics from a friend who just upgraded. The problem is they don't fit the current recessed electronics box in my console but would fit flush mounted if I repaid the current (28'x24") cut out.
I would love the collective wisdom of CSC to ensure I get this right. I really want to avoid the Starboard panel approach and think I have a plan: 1) Remove the current box 2) Cut a plug (divinycel or marine plywood) to fill the hole left by the box (close on the edge inside the console and angled away from the edge outside the console for increased "bonding" area and to ensure penetration of bonding material) 3) Strap the plug in place (flush on the inside of the console and slightly recessed from the outside) 4) Fiberglass matt the inside of the console right over the plug out to the corners (should give @ 2" of tabbing on the sides and more on the top and bottom and bond the mat to the plug) 5) Let it set up, remove the strapping and start working from the outside 6) Fill the gap between the plug and the console with bonding material (straight epoxy? epoxy and filler? ideas? This is going to have to be almost vertical since I cannot remove the console for the project) 7) Fiberglass mat over the plug and onto the outside of the console (will angle the console side of the edge as well to provide "overlap" from the mat without going "above" the current surface) 8) Fair out the repaired area 9) Roll and tip a 2 part polyurethane color matched paint 10) Mount the new electronics in the "like new" console I have done all the steps on other projects and am happy with the results but, want to make sure: 1) I am not overcomplicating this, and 2) The "repair" can handle the weight of the electronics even if I have to cut through parts of the bonded area to mount the electronics Thanks |
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