10/10/13: Completed all tasks.
- Unhook the wiring for the running lights.
- Clip the wires at the point inside the chain locker so you don’t have to re-string the wires through the pulpit (Very difficult).
- Remove the pulpit.
- Remove the lifeline connections to the pulpit.
- The turn-buckles may need to be loosened slightly, but not so much that the lines twist badly.
- Clip the loose ends somewhere on the boat so they don’t fly around.
- Unscrew the 3 bolts for each pulpit stanchion.
- It helps to put a lot of slack in the anchor chain to allow for more access.
- Tape up the holes so water can’t get into the sandwiched balsa core.
- Replace the nasty bolts at Hawaii Nut and Bolt in Honolulu.
- Remove the lifeline connections to the pulpit.
- Bring the pulpit to Diamond Welding for rewelding if required.
- One stanchion base plate was rewelded for $45.
- Prepare the boat for reinstallation.
- Clean the holes and fiberglass so the new glue sticks.
- Acetone and paint scrapers worked well.
- Check the holes for any delamination.
- The wood core sandwiched between the fiberglass layers should be widened a small amount in the holes and filled with fiberglass to prevent delamination in the future.
- The holes were all epoxied and no extra work was required.
- Clean the holes and fiberglass so the new glue sticks.
- Install the new pulpit.
- 2 people is possible, but 4 or 5 will make a cleaner finished product.
- Apply 3M 4000UV Quick-Dry at each connection point and spread thick enough to allow for a few millimeters of gasket after drying.
- I was going to use 4200, but 4000UV sounded good from online research.
- 5200 is too strong and may remove some fiberglass if uninstall is required later.
- Thread the electrical into the chain locker and place the pulpit lightly in place.
- Try not to squeeze too much 4000UV out.
- Install all the bolts and nuts (using the largest washers possible) and tighten finger tight.
- Ideally, a small amount of glue will squeeze out past the edges of the bases and a few millimeters of space vertically will act as a gasket.
- Wait about 30 minutes to 1 hour for the glue to dry tack-free and tighten the bolts some more.
- Don’t crank them down all the way, yet. Lightly wrench-tight is fine.
- Clean-up.
- The next day, finish cranking the bolts medium wrench-tight.
- Clean up the extra glue with a razor and acetone.
- Connect the electrical and test the running lights.
- Used clear silicone to waterproof wire access holes in pulpit.