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Old 26-10-2015, 15:46   #1
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DIY Toe Rail

I'm in the reseach phase of my project, we just bought a 1970 Morgan 30-1. The team on the gunwale is toast, like gone. Aluminum toe rail seems like an expensive item to add. Most websites don't even show pricing, I found one place that said $700 for 8' of it.

Correct me if I'm wrong, but isn't it just aluminum angle with holes in it?

Couldn't I just buy this and use a drill press to drill out holes?
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Old 26-10-2015, 16:53   #2
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Re: DIY Toe Rail

No way. It's a pretty special extrusion. Find some used rail.
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Old 26-10-2015, 17:23   #3
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Re: DIY Toe Rail

why not replace with teak toerail?
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Old 26-10-2015, 22:20   #4
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Re: DIY Toe Rail

good grief, of course you can make your own toe rail, alloy angle, 3x3 or what ever, then make a jig for a consistent cutout shape and go for it. I did a 110' for my new build and made a slot type cutout 2"x 1" and dressed it with a router bit. I could send a pic if you really care to see it.
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Old 27-10-2015, 04:21   #5
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Re: DIY Toe Rail

Quote:
Originally Posted by Guy View Post
No way. It's a pretty special extrusion. Find some used rail.
I've never seen a toe rail made of simple angle stock.
Crest Aluminum Products Co, Inc
Aluminum Sailboat Toe Rail: 1 9 16 x 1 1 2 Aluminum Sailboat Toe Rail @ tacomarine.com
Goiot Aluminum Toerail
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Old 27-10-2015, 08:08   #6
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Re: DIY Toe Rail

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Originally Posted by Mirar View Post
good grief, of course you can make your own toe rail, alloy angle, 3x3 or what ever, then make a jig for a consistent cutout shape and go for it. I did a 110' for my new build and made a slot type cutout 2"x 1" and dressed it with a router bit. I could send a pic if you really care to see it.
Greg
I'd love to see it. How much $$$ did you save?
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Old 27-10-2015, 08:16   #7
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Re: DIY Toe Rail

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Great links thank you
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Old 27-10-2015, 15:53   #8
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Re: DIY Toe Rail

Hi again, I used 1/2" thick x 3" 6061 flat stock and used a hole saw to cut the two ends of the slot, then cut out between the holes with a jigsaw. Took quite a few hours for sure as there is approximately a 100 feet of toe rail for the two sides. Where I wanted fairleads, I doubled up the thickness by welding another piece of 3" stock, then cutting out the slot.
It was a huge price saving but quite time consuming. Of course on my boat it is just welded to the deck but should be possible using angle material and bolting it on.
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Old 27-10-2015, 17:04   #9
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Re: DIY Toe Rail

Mirar-Please post photos of your rubrail.

Different types of heavy scedule hosing/tubing cut in half are atractive and utile rubrails.



All the Best
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Old 27-10-2015, 17:55   #10
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Re: DIY Toe Rail

Quote:
Originally Posted by Mirar View Post
Hi again, I used 1/2" thick x 3" 6061 flat stock and used a hole saw to cut the two ends of the slot, then cut out between the holes with a jigsaw. Took quite a few hours for sure as there is approximately a 100 feet of toe rail for the two sides. Where I wanted fairleads, I doubled up the thickness by welding another piece of 3" stock, then cutting out the slot.
It was a huge price saving but quite time consuming. Of course on my boat it is just welded to the deck but should be possible using angle material and bolting it on.
Looks great, why did you build your own? Was is a price decision or did you build them better than purchased toe rails?
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Old 27-10-2015, 20:13   #11
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Re: DIY Toe Rail

Hi Allen, I built my own for a couple of reasons, saved lots of money, but also the premade toe-rail is usually anodized, and I wanted to weld the rails down onto the deck. My bollards (three sets per side) are set inline with the toerails so no danger to the feet when running about on deck. I used a cheap router bit to round over the slots to make them line friendly.
regards, Greg
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Old 28-10-2015, 19:30   #12
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Re: DIY Toe Rail

Quote:
Originally Posted by allanbranch View Post
I'm in the reseach phase of my project, we just bought a 1970 Morgan 30-1. The team on the gunwale is toast, like gone. Aluminum toe rail seems like an expensive item to add. Most websites don't even show pricing, I found one place that said $700 for 8' of it.

Correct me if I'm wrong, but isn't it just aluminum angle with holes in it?

Couldn't I just buy this and use a drill press to drill out holes?
Teak, teak. teak....
There are other woods around you know?
And.... just as good and several times cheaper.
For instance, Cumaru, a Brazilian hardwood very similar to teak that could work for you. If you are diligent on your search, you can find it available in long lengths, it is mostly used for decking and hardwood floors.

Just check out this project - looks great:

New Toe Rail

Actually this is a great site and could be good reference for your projects:

Owners Projects
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Old 28-10-2015, 19:46   #13
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Re: DIY Toe Rail

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Originally Posted by SVTatia View Post
Teak, teak. teak....
There are other woods around you know?
And.... just as good and several times cheaper.
For instance, Cumaru, a Brazilian hardwood very similar to teak that could work for you. If you are diligent on your search, you can find it available in long lengths, it is mostly used for decking and hardwood floors.

Just check out this project - looks great:

New Toe Rail

Actually this is a great site and could be good reference for your projects:

Owners Projects
Replaced ours with 1-1/4 thick X 3-1/2 wide Jarrah. We started with wide boards X 9 feet long and traced the curve from the top of the thwart. One board made two pre-curved strips. Extremely hard wood. Almost no UV weathering even untreated.
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Old 28-10-2015, 19:51   #14
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Re: DIY Toe Rail

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Originally Posted by Nicholson58 View Post
Replaced ours with 1-1/4 thick X 3-1/2 wide Jarrah. We started with wide boards X 9 feet long and traced the curve from the top of the thwart. One board made two pre-curved strips. Extremely hard wood. Almost no UV weathering even untreated.
That sounds like a great job... I'd love to see pictures.
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Old 29-10-2015, 17:36   #15
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Re: DIY Toe Rail

There were two projects. Both the toe and splash rails were low in hurricane IVAN (previous owner). Photos show a few before & after.
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