Originally Posted by scottthardin
great idea. what size keenserts are you using and how big of a hole are you drilling? For example, if the outside diameter of the keenserts is 3/8" do you drill a 1/2" hole to allow for the epoxy to do its work?
From my research
, it appears that outside diameter of a keensert is about 1/8" bigger than inside diameter so a 1/4" bolt will require a keensert with an outside diameter of 3/8".
I still wonder what happens with the epoxy under the deck
and above the liner. Maybe that is why you will use fairly thick epoxy?
You can make the project
as precise as you like using a micrometer to measure a slight tolerance above the actual OD of the keensert or you can do it by eye. The size of the bolt/keensert will depend on the size of the hole in your dodger
fitting--namely that the bolt in the keensert matches the hole diameter in your dodger
fitting. The actual installation
is quite simple: First, drill a hole through the upper skin and core
material slightly larger than the OD of the keensert. Do not drill through the bottom skin! Vacuum out any remaining debris and then check the core
with a dental pick to be certain the core material is dry. If it is not, the epoxy will not work and you will need to dry it completely before installation
. If dry, lightly coat the inside of the hole with un-thickened epoxy. You can use a Q-tip for the application. Allow the 2 part epoxy to penetrate the core for a couple minutes and then mix a small amount of epoxy with high-density filler. Coat the inner surface of the keensert and the threads of the bolt with a paste wax. Wipe the outside of the keensert with Acetone. Then use a small tempera brush to apply the thickened epoxy to the inside of the hole and the outside of the keensert. Firmly push the keensert into the hole and scrape away any excess epoxy with a palette knife. Wipe the surrounding area with acetone if there are any splotches or spills of epoxy. Allow to "kick" for 24 hours, then remove the waxed bolt. If there is any residual epoxy on the threads or keensert, remove with a dental pick and re-vacuum. Now you're ready to mount your dodger support. As a final remark, the installation will become essentially monocoque since the loads imposed on the fitting will be horizontal. Hope this helps. Good luck on your project