180 DAUNTLESS Through-hull Replacement

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
tlsch377
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180 DAUNTLESS Through-hull Replacement

Postby tlsch377 » Tue Nov 17, 2020 10:05 pm

I am replacing three press-fit thru-hull fittings on my 180 DAUNTLESS. These OEM components are plastic press-fit thru-hull fittings. Two are in the engine splash well, and one is the bilge drain tube. They are different lengths. Boston Whaler sells the replacement part in one length, so they need cutting. It may seem simple to many, but I want to do it right.

Give me clear directions on the best way to cut these plastic press-fit through-fittings.

I am also replacing one thru-hull fitting that goes to the bait well which does not need cutting.

BACKSTORY: water was getting into the bilge of the 180 DAUNTLESS. Boston Whaler now is (apparently) recommending an annual inspection of the thru hulls—so there must have been problems. I found wet wood when I pulled out these press-fit thru-hulls. I hope now the wood has dried. I coated the inside [of the hull where the fitting pass through] with Get Rot, I will apply Interlux 2000e epoxy barrier coat in the holes while I am applying a new barrier coat to the stern. I will apply a generous amount of 4200 when I install the new thru-hulls. I am confident the wood is now dry and the steps I take will keep the wood strong.

Give your opinion of my repair method.

jimh
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Re: 180 DAUNTLESS Through-hull Replacement

Postby jimh » Wed Nov 18, 2020 10:09 am

tlsch377 wrote:Give your opinion of my repair method.


If you want to seal the interior of the passageway of the through-hull fittings, I would use a sealant.

If you install the plastic through-hull fittings using 3M4200, you will probably never be able to remove them again. The 3M4200 product is a very strong adhesive sealant, and it will be difficult to impossible to remove a through-hull that has been adhered in place with 3M4200.

There is a recorded presentation on youTube created by Boston Whaler which demonstrates the installation method. Because the integrity of the hull will be affected by a poor installation, I believe Boston Whaler was recommended that an authorized Boston Whaler dealer perform the repair.

The Boston Whaler presentation that demonstrates replacement of plastic through hull drains can be viewed at

https://www.youtube.com/watch?v=Zby76eoKO-I

Note: at no time is use of 3M4200 recommended in this demonstration. The link jumps ahead about two minutes into the presentation to the actual demonstration section.

jimh
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Re: 180 DAUNTLESS Through-hull Replacement

Postby jimh » Wed Nov 18, 2020 10:21 am

tlsch377 wrote:I am replacing three press-fit thru-hull fittings on my 180 DAUNTLESS.


I am not familiar with use of a press-fit plastic through hull fitting on Boston Whaler boats. What is the model year of the boat?

The fittings used in the demonstration (linked above) are two-part fittings that thread together.

tlsch377
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Re: 180 DAUNTLESS Through-hull Replacement

Postby tlsch377 » Wed Nov 18, 2020 8:11 pm

Thanks JimH.

My boat is a 2005 180 Dauntless, and the thru-hull fittings in the engine splash well and the bilge drain hole are press fit.

I worked with Sue in Wisconsin to get the parts from Boston Whaler. They were actually shipped directly to me from Boston Whaler. Boston may well use threaded thru-hulls now, but they did not on this model.

I think the 3M 5200 is the sealant you are referring to that will not allow for easy replacement.

I think the 3M4200 stays flexible and should be the correct sealant.

I coated the wood core with get rot and then with Interlux 2000e. I will next coat the holes with 4200 and press the two part thru hulls together.

My hope was to get advice on how to cut the pipes so they are flush.

jimh
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Re: 180 DAUNTLESS Through-hull Replacement

Postby jimh » Thu Nov 19, 2020 8:27 am

I am aware of both 3M5200 and 3M4200.

Before using 3M4200, I recommend you get advice from Boston Whaler on their recommended sealant.

If you used 3M5200 you would never get the through-hull out. With 3M4200 to get the fitting out will be very difficult.

biggiefl
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Re: 180 DAUNTLESS Through-hull Replacement

Postby biggiefl » Thu Nov 19, 2020 10:47 am

Do not use 4200. Buy just a plain sealant or caulk like BoatLife.
On my 24th Whaler. Currently in the stable: 86 18' Outrage, 81 13' Sport(original owner), 87 11' Sport, 69 Squall(for sale cheap).

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GoldenDaze
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Re: 180 DAUNTLESS Through-hull Replacement

Postby GoldenDaze » Thu Nov 19, 2020 3:13 pm

There's an extensive discussion at

http://continuouswave.com/forum/viewtopic.php?f=6&t=2729&p=20455#p20876

I used 3M 4200 on my replacement drains, and I may well regret it later but it's too late now.
2003 160 Dauntless Golden Daze

tlsch377
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Re: 180 DAUNTLESS Through-hull Replacement

Postby tlsch377 » Thu Nov 19, 2020 5:33 pm

Thanks JimH - I did check with Boston Whaler; they recommend SikaFlex 291, which I will use. I returned the 3M4200.

All the discussions and photos of rotted wood make me aware that these thru hulls do need regular attention, so if I need to pull these every couple years, I don't want to be wrestling with the sealant-adhesives. The wood core was wet around the thru hulls, more at the splash well than the drain, and there was no evidence that any caulk or sealant had been used. And worse, the wood core showed no sign that it had been sealed before the thru hulls were installed.

Some screw holes that mounted the speedometer sensor paddlewheel were wet as well. I used pipe cleaners to swab the holes with acetone and coat them with Interlux two part 2000e. Then I filled the holes with wood dowel coated with 2000e. I hope that will be enough.

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Phil T
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Re: 180 DAUNTLESS Through-hull Replacement

Postby Phil T » Thu Nov 19, 2020 5:58 pm

Worth noting -

Sikaflex®-291 is a 1-component, marine grade polyurethane elastomeric adhesive and sealant. Used by many boat builders, its fast cure time makes it ideal for applications where speed is important.


cf: https://usa.sika.com/dms/getdocument.get/006a239b-1e1a-3eab-a634-6c9b773cacf4/ipd-pds-sikaflex291-us.pdf
Member since 2003
1992 Outrage 17, 1992 Evinrude 115