Roll-top Door Console Material; Aluminum Replacement

  ContinuousWave
  Whaler
  Moderated Discussion Areas
  ContinuousWave: Whaler Repairs/Mods
  Roll-top Door Console Material; Aluminum Replacement

search | FAQ | profile | register | author help

Author Topic:   Roll-top Door Console Material; Aluminum Replacement

yellowlab posted 10-25-2014 08:53 AM ET (US)
My 1992 Outrage shows signs of utraviolet light damage on the roll top locking door. Where can material to replace it be purchased? It's plastic. Aluminum might be a better replacement?
jimh posted 10-25-2014 10:25 AM ET (US)
When seeking a replacement part for an original part of a Boston Whaler boat, a good place to start when seeking a source is Boston Whaler customer service. If Boston Whaler no longer offers a replacement part, Boston Whaler customer service is typically very glad to offer you advice on how to obtain a similar part, or to offer advice on the original manufacturer of the part, if Boston Whaler did not make the part themselves. Also, certain Boston Whaler dealers are very helpful in locating parts. In particular, TWIN CITIES MARINE in Wisconsin has a long history and is frequently endorsed for being a great source of parts.
wjd posted 10-25-2014 03:34 PM ET (US)
I have a 1992 17' outrage. The lifting/slide away door on the console of my boat is made of black acrylic - almost opaque. Assuming that our boats are similar, it would be a simple task to duplicate your door. A local plastic supplier may sell off-cuts or small part sheets. Bring your door in to match the plastic. You might make a MDF template and then cut the part using a router. Acrylic sheet also cuts well on a table saw with the right blade. I use an 80 tooth 10" Triple chip blade with a 10 degree rake. Sand the edges with progressively finer sandpaper and finish with a quick flame polish.
saumon posted 10-26-2014 04:21 AM ET (US)
I'm pretty sure they were made of polycarbonate (Lexan TM), and NOT acrylic (Plexiglas TM)...
yellowlab posted 10-26-2014 08:47 AM ET (US)
These are not the port and starboard acrylic smoked doors. And yes those are sadly acrylic versus lean [Lexan] as lean [Lexan] wouldn't shatter like acrylic did. The port side of mine shattered as the lock catch didn't close and the wind caught it when trailers, it hit the console grab handle, but that's another issue...
What I'm referring to is the locking roll top electronics cubby door that rolls into the console in front of the steering wheel. I was able to do a temporary fix by removing the damaged section and shortened the whole assembly, but looking for a replacement sleeves in powder coated aluminum versus plastic. It's like having to replace the venetian blinds, section by section.
jimh posted 10-27-2014 05:23 AM ET (US)
What is "lean"? Is it a type of material? Or, did you mean Lexan? Were you composing your reply with some device that automatically corrects spelling errors and changed Lexan to lean?
yellowlab posted 10-27-2014 11:36 AM ET (US)
Oh yes Jim, the not so smart thing about smart phones. Yes, Lexan.
yellowlab posted 10-27-2014 05:43 PM ET (US)
Seems that I am not the only one with the problem. I have emailed Whaler to see if I can track down the part(s). I did end up doing the same 'fix' as the forum member did on his Outrage.
http://continuouswave.com/ubb/Forum3/HTML/015916.html
I'll report back on my findings and what I did for the repair.
yellowlab posted 10-27-2014 05:44 PM ET (US)
FYI, here is the reply I got from Whaler regarding the roll up door:
Unfortunately, the manufacturer that had originally produced the roll up door on the console of the 19II Outrage has since gone out of business...sorry. I do not have another source for a reproduction.
I'm wondering if it may be possible to add some type of electronics box or the door only, made out of marine plastic (King Starboard).
Below is one on line source. They should be able to work with you on the specific size needed.
http://www.boatoutfitters.com/
Regards,
Chuck Bennett
Boston Whaler, Inc.
jimh posted 10-28-2014 03:25 PM ET (US)
Oh the joys of the smart phone. That same nonsense goes on with the word "antennas" which some smart phones--apparently ones designed by insect collectors--thinks is spelled antennae. After working in radio communications for 45-years I have never heard anyone refer to a radio antenna in the plural as antennae, but every smart phone thinks that is the correct spelling. I will add Lexan to the list of words to watch out for when writing with a smart phone.
saumon posted 10-28-2014 06:47 PM ET (US)

quote:
yellowlab posted 10-26-2014 08:47 AM ET (US)
These are not the port and starboard acrylic smoked doors. And yes those are sadly acrylic versus lean [Lexan] as lean [Lexan] wouldn't shatter like acrylic did. The port side of mine shattered as the lock catch didn't close and the wind caught it when trailers, it hit the console grab handle, but that's another issue...
If these smoked plastic doors are like the ones on my console...
http://www.myfishingpictures.com/data/500/IMG_07921.jpg
http://www.myfishingpictures.com/data/500/console4.jpg
...they were made of Lexan. At least that's what was written on the original packing list of my 1991 Outrage 17.
http://www.myfishingpictures.com/data/500/1991_Outrage_17_packing_list. jpeg
Qtrmeg posted 10-29-2014 05:54 AM ET (US)
That is called a tambor door, and can be made of any rigid material you want.
yellowlab posted 10-29-2014 12:46 PM ET (US)
Thanks Qtrmeg for the proper definition. Looks like this company makes aluminum tambor doors. Will see if I can retro fit something to the proper width and height for the Outrage cabinet.
http://www.rollok.com/Aluminum_Tambour_Doors.html
RE: the Lexan doors, I've not know Lexan to shatter like it did when the lock catch didn't hold and the wind caught the door. I was able to Gorilla glue it back together for a temporary fix, but the hinge should have really been mounted on the bow end so it opens the opposite way as to prevent accidental breakage. I'll probably just craft up a couple of UV starboard doors as a fix.

Hop to:

Contact Us | RETURN to ContinuousWave Top Page

Powered by: Ultimate Bulletin Board, Freeware Version 2000
Purchase our Licensed Version- which adds many more features!
© Infopop Corporation (formerly Madrona Park, Inc.), 1998 - 2000.

Author	Topic: Roll-top Door Console Material; Aluminum Replacement
yellowlab	posted 10-25-2014 08:53 AM ET (US) My 1992 Outrage shows signs of utraviolet light damage on the roll top locking door. Where can material to replace it be purchased? It's plastic. Aluminum might be a better replacement?
jimh	posted 10-25-2014 10:25 AM ET (US) When seeking a replacement part for an original part of a Boston Whaler boat, a good place to start when seeking a source is Boston Whaler customer service. If Boston Whaler no longer offers a replacement part, Boston Whaler customer service is typically very glad to offer you advice on how to obtain a similar part, or to offer advice on the original manufacturer of the part, if Boston Whaler did not make the part themselves. Also, certain Boston Whaler dealers are very helpful in locating parts. In particular, TWIN CITIES MARINE in Wisconsin has a long history and is frequently endorsed for being a great source of parts.
wjd	posted 10-25-2014 03:34 PM ET (US) I have a 1992 17' outrage. The lifting/slide away door on the console of my boat is made of black acrylic - almost opaque. Assuming that our boats are similar, it would be a simple task to duplicate your door. A local plastic supplier may sell off-cuts or small part sheets. Bring your door in to match the plastic. You might make a MDF template and then cut the part using a router. Acrylic sheet also cuts well on a table saw with the right blade. I use an 80 tooth 10" Triple chip blade with a 10 degree rake. Sand the edges with progressively finer sandpaper and finish with a quick flame polish.
saumon	posted 10-26-2014 04:21 AM ET (US) I'm pretty sure they were made of polycarbonate (Lexan TM), and NOT acrylic (Plexiglas TM)...
yellowlab	posted 10-26-2014 08:47 AM ET (US) These are not the port and starboard acrylic smoked doors. And yes those are sadly acrylic versus lean [Lexan] as lean [Lexan] wouldn't shatter like acrylic did. The port side of mine shattered as the lock catch didn't close and the wind caught it when trailers, it hit the console grab handle, but that's another issue... What I'm referring to is the locking roll top electronics cubby door that rolls into the console in front of the steering wheel. I was able to do a temporary fix by removing the damaged section and shortened the whole assembly, but looking for a replacement sleeves in powder coated aluminum versus plastic. It's like having to replace the venetian blinds, section by section.
jimh	posted 10-27-2014 05:23 AM ET (US) What is "lean"? Is it a type of material? Or, did you mean Lexan? Were you composing your reply with some device that automatically corrects spelling errors and changed Lexan to lean?
yellowlab	posted 10-27-2014 11:36 AM ET (US) Oh yes Jim, the not so smart thing about smart phones. Yes, Lexan.
yellowlab	posted 10-27-2014 05:43 PM ET (US) Seems that I am not the only one with the problem. I have emailed Whaler to see if I can track down the part(s). I did end up doing the same 'fix' as the forum member did on his Outrage. http://continuouswave.com/ubb/Forum3/HTML/015916.html I'll report back on my findings and what I did for the repair.
yellowlab	posted 10-27-2014 05:44 PM ET (US) FYI, here is the reply I got from Whaler regarding the roll up door: Unfortunately, the manufacturer that had originally produced the roll up door on the console of the 19II Outrage has since gone out of business...sorry. I do not have another source for a reproduction. I'm wondering if it may be possible to add some type of electronics box or the door only, made out of marine plastic (King Starboard). Below is one on line source. They should be able to work with you on the specific size needed. http://www.boatoutfitters.com/ Regards, Chuck Bennett Boston Whaler, Inc.
jimh	posted 10-28-2014 03:25 PM ET (US) Oh the joys of the smart phone. That same nonsense goes on with the word "antennas" which some smart phones--apparently ones designed by insect collectors--thinks is spelled antennae. After working in radio communications for 45-years I have never heard anyone refer to a radio antenna in the plural as antennae, but every smart phone thinks that is the correct spelling. I will add Lexan to the list of words to watch out for when writing with a smart phone.
saumon	posted 10-28-2014 06:47 PM ET (US) quote: yellowlab posted 10-26-2014 08:47 AM ET (US) These are not the port and starboard acrylic smoked doors. And yes those are sadly acrylic versus lean [Lexan] as lean [Lexan] wouldn't shatter like acrylic did. The port side of mine shattered as the lock catch didn't close and the wind caught it when trailers, it hit the console grab handle, but that's another issue... If these smoked plastic doors are like the ones on my console... http://www.myfishingpictures.com/data/500/IMG_07921.jpg http://www.myfishingpictures.com/data/500/console4.jpg ...they were made of Lexan. At least that's what was written on the original packing list of my 1991 Outrage 17. http://www.myfishingpictures.com/data/500/1991_Outrage_17_packing_list. jpeg
Qtrmeg	posted 10-29-2014 05:54 AM ET (US) That is called a tambor door, and can be made of any rigid material you want.
yellowlab	posted 10-29-2014 12:46 PM ET (US) Thanks Qtrmeg for the proper definition. Looks like this company makes aluminum tambor doors. Will see if I can retro fit something to the proper width and height for the Outrage cabinet. http://www.rollok.com/Aluminum_Tambour_Doors.html RE: the Lexan doors, I've not know Lexan to shatter like it did when the lock catch didn't hold and the wind caught the door. I was able to Gorilla glue it back together for a temporary fix, but the hinge should have really been mounted on the bow end so it opens the opposite way as to prevent accidental breakage. I'll probably just craft up a couple of UV starboard doors as a fix.