Installing Aluminum Toerail

[SkiprJohn]

Thanks for the suggestion. I think with using a generous dollop of 5200 though that every 8" top and every 8" sides is going to be all I need.
At first I was thinking even less often that that.
Thanks again.
Kind Regards,
JohnL

[SkiprJohn]

I dry fit one 20 foot section several months ago then had lots of house guests and didn't get back to it.
Starting again. What a pain in the ___. I don't know if the local True Value Hardware and General Store has enough beer to see me through this project.
Wish me luck.
JohnL

[SkiprJohn]

Well! This last Monday I got the first section installed on the port quarter. It took about 40 1/4-20 4" through bolts (machine screws) through the sides of the 20 foot section and about the same amount of 8" 1/4-20 bolts through the top of the rail with a generous dollop of 3M 5200 under the rail. Of course I learned a lot on this first installation and will be faster and better on the next. I think it is very strong.
Lesson learned. Wear rubber gloves. Second lesson learned: Have plenty of line and come alongs handy to bend the aluminium extrusion around to meet the deck edge. Keep cold beer on hand.
Kind regards,
JohnL

[Extemporaneous]

Originally Posted by SkiprJohn

Well! This last Monday I got the first section installed on the port quarter. It took about 40 1/4-20 4" through bolts (machine screws) through the sides of the 20 foot section and about the same amount of 8" 1/4-20 bolts through the top of the rail with a generous dollop of 3M 5200 under the rail. Of course I learned a lot on this first installation and will be faster and better on the next. I think it is very strong.
Lesson learned. Wear rubber gloves. Second lesson learned: Have plenty of line and come alongs handy to bend the aluminium extrusion around to meet the deck edge. Keep cold beer on hand.
Kind regards,
JohnL

I'm sure it will feel SOOO good when it is complete. I know that it did when I got mine complete (212 5/16th 316 ss machine screws).
Good luck.
Extemp.

[SilentOption]

I replaced all the wood toe rail on my CSY with slotted toe rail.

The aft deck needed about a 1/2 inch relief so I wound up putting wood back down after all.

Your very first post asks how many crews and how many through-bolts.

In my case the boat pretty much dictated that. Some areas were impossible to through-bolt so we used screws.

In areas where we were sure we'd be securing tackle we through-bolted every hole that we could.

I put up 4 sections 17 feet long approximately. After dry fit up and starter holes were in place I put down the 5200. It was still a bit messy but I managed to clean it up.

I had one helper but the best tool was large clamps and lots of them. It is virtually impossible to get the fit you need by holding the rail in place by hand.