Outrage Electronics Door Repair

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
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Phil T
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Outrage Electronics Door Repair

Postby Phil T » Wed Jan 18, 2017 1:52 pm

The electronics box on the early 1990's Outrage console has a plexiglass door that is hinged. The hinge is attached with screws that do not penetrate.

On my recently acquired 1992 Outrage 17, several of these screws are stripped or missing. Should I attempt replacement screws or modify the design by through-bolting. I presume I can drill the holes out with a drill bit in reverse on low speed.

The console box looks like this:
DSC01917_2.jpg
DSC01917_2.jpg (50.33 KiB) Viewed 2452 times


The hinged door:

IMG_0203.jpg
IMG_0203.jpg (24.86 KiB) Viewed 2452 times


Appreciate your help.
Member since 2003
1992 Outrage 17, 1992 Evinrude 115

Jefecinco
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Re: Outrage Electronics Door Repair

Postby Jefecinco » Wed Jan 18, 2017 7:33 pm

Phil,

Through bolting is probably the most "bullet proof" solution using self locking nuts with, perhaps, a small fender washer. My inclination would be to see if some heavy gauge leader monofilament through the hole in two or three locations around the perimeter would provide enough biting surface for the same size screw as the originals. Otherwise I would consider trying the next size larger screw in the old hole or a combination of both. If uniformity is essential all the screws could be replaced with the next larger size.
Butch

jimh
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Re: Outrage Electronics Door Repair

Postby jimh » Thu Jan 19, 2017 9:29 am

Plexi-glas material is difficult to work with self-tapping screws. It can easily crack. I think using machine screws with elastic stop nuts would be a solution. Another approach: tap the Plexi-glas and use machine screws with some thread locking material.

PeteB88
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Re: Outrage Electronics Door Repair

Postby PeteB88 » Thu Jan 19, 2017 11:04 pm

Phil - the lower stash box on my 17 console never had the plexi half cover. We used it as a foot rest but it's not great. I'd like to get one for mine, could seriously use that storage area but have no idea if a proper one exists as spare part or where to source one.

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Phil T
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Location: NYC then MA, NY, ME,DC,ME, now Kentucky
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Re: Outrage Electronics Door Repair

Postby Phil T » Fri Jan 20, 2017 1:33 pm

I rested my foot on the lower storage part on my 1991 and almost broke it.

If interested, I can make a paper template of mine and send it to you. Any shop can fab it for you or you could buy a sheet and DIY.
Member since 2003
1992 Outrage 17, 1992 Evinrude 115