toe rail replacement

[tsl]

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.

[Orion Jim]

You are considering a monumental job. How much of the toerail has significant damage. How much is cosmetic as opposed to structural. I'd be inclined to live with the repairs you've already effected, especially since the profile shot in your blog looks great as is.

[tsl]

Originally Posted by Jim Walsh

You are considering a monumental job. How much of the toerail has significant damage. How much is cosmetic as opposed to structural. I'd be inclined to live with the repairs you've already effected, especially since the profile shot in your blog looks great as is.

Nothing is structural. The toe rail is broken up by the Stanchion bases so I must remove three 8 foot sections. I do agree , this is not something I am taking lightly.

Thanks for the input.