Easy stern light replacement for Outrage/Revenge

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Author Topic:   Easy stern light replacement for Outrage/Revenge

Over the LINE posted 12-05-2006 03:20 PM ET (US)
Here is a hot, fast and cheap method for attaching the Perko stern navigation light to the aluminum tubing upright used as part of the stern light assembly on many classic Outrage and Revenge models.
I had seen a method using stainless components and a fabricator but figured there must be an easier way. I happened to have scrap ¼” black Starboard lying around and decided this was the ticket.
Using a hole saw I cut several pieces just larger than the tubing I.D. then cut one piece approximately the same size as the light assembly base.
http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=sternlight2.jpg
Next I used a bolt and epoxy to bond the pieces together.
http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=sternlight3.jpg
I then removed the bolt used during the bonding process and fine tuned the fit using a little sandpaper. I over drilled the center hole to better accommodate wiring and attached the light assembly.
http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=Sternlight1.jpg
Finally I inserted the assembly into the aluminum tubing base and attached with a set screw. I had originally intended to epoxy the parts together but the fit was so tight I opted for just a set screw.
http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=sternlight4.jpg
It is not yet time tested and may well fail under “torture tests” but it was easy to make and I figured some originals were made of plastic. I am sure you could also fabricate this using teak or mahogany. I am trying to get away from wood and owned the Starboard.
Hope this helps someone else.

MyOutrage posted 12-05-2006 05:33 PM ET (US)
Nice job and a whole lot easier and cheaper than fabricating from stainless steel.... trust me, I know
http://continuouswave.com/ubb/Forum1/HTML/010329.html
Over the LINE posted 12-05-2006 11:02 PM ET (US)
MyOutrage,
I saw your version. Looked great and I am sure it is superior to my "hot, fast and cheap" model. I have had a lot of things custom fabricated. This one I figured I could do "on the cheap".
Thanks for putting together your info. I used it as inspiration/partial parts list for my job.
Buckda posted 12-06-2006 04:49 PM ET (US)
Excellent post. This is very useful info for people restoring their boats. Thanks for sharing your idea.
Dave
kamie posted 12-06-2006 06:24 PM ET (US)
I already have it bookmarked as I need to replace the stern light when I pull the t-top.

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Author	Topic: Easy stern light replacement for Outrage/Revenge
Over the LINE	posted 12-05-2006 03:20 PM ET (US) Here is a hot, fast and cheap method for attaching the Perko stern navigation light to the aluminum tubing upright used as part of the stern light assembly on many classic Outrage and Revenge models. I had seen a method using stainless components and a fabricator but figured there must be an easier way. I happened to have scrap ¼” black Starboard lying around and decided this was the ticket. Using a hole saw I cut several pieces just larger than the tubing I.D. then cut one piece approximately the same size as the light assembly base. http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=sternlight2.jpg Next I used a bolt and epoxy to bond the pieces together. http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=sternlight3.jpg I then removed the bolt used during the bonding process and fine tuned the fit using a little sandpaper. I over drilled the center hole to better accommodate wiring and attached the light assembly. http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=Sternlight1.jpg Finally I inserted the assembly into the aluminum tubing base and attached with a set screw. I had originally intended to epoxy the parts together but the fit was so tight I opted for just a set screw. http://smg.photobucket.com/albums/v442/OTL4343/18%20Outrage/ ?action=view¤t=sternlight4.jpg It is not yet time tested and may well fail under “torture tests” but it was easy to make and I figured some originals were made of plastic. I am sure you could also fabricate this using teak or mahogany. I am trying to get away from wood and owned the Starboard. Hope this helps someone else.
MyOutrage	posted 12-05-2006 05:33 PM ET (US) Nice job and a whole lot easier and cheaper than fabricating from stainless steel.... trust me, I know http://continuouswave.com/ubb/Forum1/HTML/010329.html
Over the LINE	posted 12-05-2006 11:02 PM ET (US) MyOutrage, I saw your version. Looked great and I am sure it is superior to my "hot, fast and cheap" model. I have had a lot of things custom fabricated. This one I figured I could do "on the cheap". Thanks for putting together your info. I used it as inspiration/partial parts list for my job.
Buckda	posted 12-06-2006 04:49 PM ET (US) Excellent post. This is very useful info for people restoring their boats. Thanks for sharing your idea. Dave
kamie	posted 12-06-2006 06:24 PM ET (US) I already have it bookmarked as I need to replace the stern light when I pull the t-top.