1992 Challenger 25 Dive Door Structure

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
kekai808
Posts: 1
Joined: Wed Apr 20, 2022 6:18 pm

1992 Challenger 25 Dive Door Structure

Postby kekai808 » Wed Apr 20, 2022 6:40 pm

I bought a 1992 CHALLENGER 25 that is really beat up. My concern is for damage around the dive door, where delimitation and cracking exist. I assume in the laminate there is an aluminum plate that is corroding and expanding, and that is what is causing the cracking in the fiberglass.

Q1: what is the structure around the dive door on a 1992 CHALLENGER 25 boat?

Give me advice before I start cutting open the area around the dive door. I have restored several Boston Whaler boats before, but never one with a dive door.

jimh
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Location: Michigan, Lower Peninsula
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Re: 1992 Challenger 25 Dive Door Structure

Postby jimh » Thu Apr 21, 2022 6:35 am

I have never seen aluminum expand in volume due to exposure to the elements. Typically aluminum just develops a surface oxidation. I cannot imagine that an embedded aluminum reinforcement plate would undergo an expansion in its volume sufficient to cause displacement and cracking of fiberglass laminate. An aluminum plate might gain a few thousandths of an inch in a surface layer of oxidation.

conch
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Joined: Sat Oct 17, 2015 8:43 am
Location: Florida Keys,Hawaii,Mississippi

Re: 1992 Challenger 25 Dive Door Structure

Postby conch » Sun Apr 24, 2022 3:38 pm

Show pictures of the area [of the CHALLENGER 25 dive door that has damage]. They might save you from a thousand wrong answers.

Three door sizes were offered.

Q2: what is the width of the dive door under discussion?

Q3: is there a stainless steel guard around the door opening?

Q4: do you have the door?

Q5: do you have the ladder?