Top-side teak handrail replacement - curves

[pgrantbyc]

Hello all,

My new-to-me Tanzer 22's top-side handrails are tired. The previous owner threw in some replacements seemingly made of IPE instead of teak, they never got around to installing.

I've seen articles discussing replacement with steel tubing etc.

I'm thinking of doing the replacement job myself, but I'm worried the new rails will be too stiff to bend into place to hug the topside curves.

I plan on using a story stick to precisely record the hole spacing and to pre-drill the handrails in my shop. I also plan on using self-tapping stainless steel screws into the rails from the bottom (I will build the same way the manufacturer did it, notwithstanding everyone who uses nutted bolts and their opinion).

I was thinking of starting from the middle and working my way out, bending the rail into alignment. Is this doable without too much grief? Does anyone know how thick the top deck is? (so I can order the right length screws).

My sealant will be butyl tape. Any advice on how to apply it?

Thank you!

Still 8 weeks to crane day. Still too cold to do any of this...

[Copacabana]

Ipê will be pretty tough to bend, but it will last many decades. I would recommend making and cutting little fiberglass "pads" to fix to the deck with thickened epoxy to raise the hand rail bases off the deck. This will help to prevent leaks and preserve the wood. Butyl is a good choice for the job. Bevel the wood a little around the screw holes to make a "gasket" when you tighten the screws.

[tkeithlu]

Getting the holes right at the shop would require doing the bending before you drill, and even then would be tricky. 0.25 mm of error would mean the new screws would not fit the old holes. It might be better to bend the railing at the boat, then use Copacabana's idea of raised pads, and then drill new holes. Just fill the old ones with 3M 5200 or epoxy.

[Bill O]

We have ipe hand rails and caps on our bulwarks. A PO had the work done for the caps and are bent nicely to fit the curve of the boat. Our hand rails are straight. It is tough stuff and is very easy to maintain. It just needs a cleaning then oiled once a year and it looks good.
Have never done it w/ipe, but making a steam tray/tube should allow you to bend it after an hour or so of steaming.

[jamhass]

A piece of door skin (thin plywood) laid against the deck makes a great template for transferring the hole locations from the curved deck to the handrails (or vice-versa).

[silkie]

Are you going to use the old coach roof holes, or drill new holes?