I have a 1983 O'day 39. I refurbished it a few years back. At that time I had no real solution for significant toe rail damage in the form of gouges and galling from what I would guess was constant contact with a concrete piling. I used All Metal, an aluminum
filled bondo like filler that did a reasonable job filling the surface and blending in. At least hiding the damage to a casual view. You can see the repair (slightly darker shade on the toe rail)on this photo
just forward of the shrouds and again at midships much less noticeable. PANTA RHEI - Panta Rhei the Journey
I was willing to accept this repair as the only alternative would be to have toe rail sections machined, and anodized to match. Too much $$$$
I just happened to search for O'day 39 toe rail and found that Crest Aluminum
now stocks exact replacement toe rail.
So now the question is : How to I replace and seal it. The toe rail is thru-bolted through the hull deck
joint and then completely glassed in on the inside.
I intend to drill out each bolt since I assume the bolts will not budge after being glassed in. I'm thinking I may try to bed
the toe rail with Butyl tape and use self sealing bolts and forgo the the fiber glass on the inside unless of coarse it leaks
. I then can seal it with fiberglass
Anyway... I'm look for opinions and suggestions. thanks in advance for your help.