CONTINUOUSWAVE

I need suggestions on how to replace a transom trim end cap on the port side of the transom of a 2005 270 OUTRAGE.

I believe the OEM part was #1771158 made by Sailing Specialty, but it is no longer available.






The rub rail is Barbour Plastics R1647: Barbour says they do not make an end cap for this rub rail.

I have tried with little success trying to customize a plastic piece using a heat gun and an oven, just not satisfied with the outcome. The original was ABS.

I have attached the damaged side photo, and the intact starboard side.

ASIDE
A detailer broke and discarded the piece.

This is a bit far-out but in the modern world entirely possible:

• remove the good starboard part
• perform a 3D scan of the part with a scanner than can generate a 3D-printer file
• manipulate the file to make a mirror image so it fits on the port side
• load the 3D printer with appropriate plastic material
• print a new part.

There may even be some sort of custom 3D printing service that could do all this for you. Whether this is a reasonable cost approach will depend on the 3D printing shop price estimate.

Thanks Jim.

I am exploring all options, including fabrication, fiberglass, modification, and salvage, and So far all are dead ends.

Q2: could I just [laminate fiber-]glass over [the remains of the damaged trim end cap]?

Barbour Plastics does not make an end cap for that large rub rail, and no other supplier (such as TACO) has [a rub rail end cap] that will work.

Another idea:

• purchase some KING StarBoard in appropriate thickness, perhaps 1.5-inches
• cut, file, grind and shape the KING StarBoard into the desired shape
• install the KING StarBoard in place of the damaged end cap.

KING StarBoard is not particularly hard and you should be able to work it into shape. As an alternative, make the end cap from Balsa wood, then use epoxy resin with filler to add a hard skin to it, and paint it white.

Like most endcaps it does not look like these are left and right. One fits both sides. Search on the Internet for a contract 3D printer shop and ask them to make it for you. You may have to send them the good one for a few days but so what. They can usually work with the same material or often a better choice of material.