Please Help - Engine Cover/Sunpad Repair

[bmies]

I'm taking the family to a rented island home tomorrow, and we can only get there on our boat. This afternoon all six hinge bolts pulled right out of the plywood on the sunpad/engine cover. On the bolts are remnants of what I assume to be heavily corroded t-nuts, and some plywood came along for the ride too.

Please share any advice you can offer. I've got to come up with a solution even if only a temporary fix until something more permanent can be done.

 

[Woodonglass]

Re: Please Help - Engine Cover/Sunpad Repair

Pics would really help us to See What you see and come up with a possible solution.

 

[further]

Re: Please Help - Engine Cover/Sunpad Repair

I'm in the process of rebuilding my sunpad, had similar issues except upon taking it apart I found that the wood wasn't actually rotten just stripped from stress. The wood is marine grade, 17 years old and in good shape but stressed and weak at the hinges and shocks which were rusted out and vinyl a little cracked so I decided to rebuild it complete. Post some pics up, not sure however that there is an easy and quick fix for this.

 

[bmies]

Re: Please Help - Engine Cover/Sunpad Repair

Sorry for the poor pics. I brought the cover home with me, and by the time I had the camera it was dark. Its a 2007 Larson Senza and the entire cover was replaced under warranty in 2011, so it is only a few years old.

 

[bmies]

Re: Please Help - Engine Cover/Sunpad Repair

Here are a couple pics of one of the hinges and bolts with the remainder of very corroded nuts.



Thanks for any hep you can offer.

 

[Woodonglass]

Re: Please Help - Engine Cover/Sunpad Repair

Here's what I'd do. I'd use a Drill with a 1" Forstner Bit to drill a flat bottomed hole about just shy of going all the way thru the existing piece. I'd then buy a piece of 1" hardwood dowel and slice off a piece that would be the depth of the hole. Then drill a hole in the patch pieces to accept the T-nuts. Mix up some 5 minute epoxy and plug the holes with the T-Nut patches. Put scotch tape over bottom of the t-nuts so epoxy does not get in the threads. This should be a good fast strong temp fix you can do in an hour or less. Hopefully this BAD drawing will help convey what I'm trying to say...

 

[bmies]

Re: Please Help - Engine Cover/Sunpad Repair

Thanks Woodonglass for taking the time to come up with a solution.

Unfortunately, the plywood seems to be pretty water logged, and I think it will take too long to dry out enough for the epoxy to bond. I think my best temporary solution at this point is to sandwich the 3/4 ply with an aluminum plate on the backside of the ply, under the upholstery. I can't believe I'm already seeing rot in the ply. As this was replaced, by Larson, only a few years ago, I would have assumed better quality.

The pad is at a marine repair shop and will go to the upholstery shop right after. I'm swamped with last minute work this morning, so I've had to hire out this fix. Anyways, thanks for the help, but it looks like I'll be replacing the ply soon.