posted 07-01-2006 08:32 PM ET (US)
I had the same problem with my ‘99. I must admit I was extremely disappointed that Whaler did not seal the fitting properly. Also, my drain plug was not properly sealed. Quite simply, it is a matter of poor workmanship in addition to substandard hardware. The fix is simple. First, order the new parts and you will see how they work. The thru-hull is a male/female connection that locks together. While you are at it, order all new fittings for every thru hull as you will probably want to replace them as well. (Contact Sue at Twin Cities as she is very knowledgeable.)
Remove the old thru-hull. You will probably be able to pull it apart in conjunction with pliers and a screw driver. Don't be afraid to destroy the old fitting in the process. However, do not damage to gel coat especially at the lip of the hole that has been drilled through the hull. Clean off the old sealant, which I believe is a sikaflex product. Assuming the opening is dry, you can proceed with installation.
First, size the new fitting. Assuming the factory sized it properly you can use the old fitting as a template. Once cut, prep and clean all of the surfaces. I would lightly sand the connection points. Once clean, place copious amounts of your preferred sealant on the inside of the hole through the hull in order to seal the foam. Your finger will be a great applicator. Also, place ample amounts of sealant on the fitting -lifecaulk, 4200, etc. I would avoid 5200 as you will probably be doing this again in the future as the substandard fittings deteriorate with age
Once the sealant is in place, two people are helpful in putting the fitting together. It is as simple as lining it up and squeezing together. An appropriately sized bolt, with two large washers and nut will help you squeeze the fitting together and also act as a vice while it dries. Once in place, clean off the excess sealant and allow to dry.
If you decide that you don't want the cheap factory hardware, let me know where you find a better fitting. Good luck.