Modifications, repairs and improvements, 28TE

[Norseman]

Removed old light, found rot damage to the core.
Will fix that before new installation.

Ugh, another project. So much for the simple swap-out.

Aye, no big deal.
The access is excellent, sunny Florida will dry out most of the damage, if not, my heat-gun will do the rest.
I plan to drill out every infected hole, dry more with heat-gun, inject epoxy in porous, rotted but dry areas, insert and epoxy teak bungs, cure, epoxy over and under, then drill new holes for the new light, etc.
Also plan to use a PVC conduit running from new light to the face of the cabin just above center windshield. (After drilling 1” holes to run new wire harness with connectors.)
Sounds like work, but I am retired, need something to keep me out of the bars and this little project is doable with minimal labor and money.
All good.

[Norseman]

Search light project is going slow due to rain but making progress: Poured 3 ounces epoxy down the hole for the search light wiring harness in the cabin top today.
Will let that sink in and cure, then another batch in a day or two.
Identified PVC pieces, drilled holes and bent the PVC with a heat gun in preparation for the big finale when everything comes together.
Stay tuned.

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[Norseman]

Another 2 ounces or so to fill the void.

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[Norseman]

Coring above center windshield appears to be plywood.
(For some reason I thought it would be balsa wood.)

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[Bluewater]

Norseman, what paint will you be using on the wheelhouse roof?

[Norseman]

Norseman, what paint will you be using on the wheelhouse roof?

Not planning to paint it for now, at the next haul-out I will ask the yard’s paint department what they recommend.
The old paint is holding up somewhat, but oxidized and chalky.

[Norseman]

Finally done with search light project: Took several days to pour 5 Oz of epoxy down the hole, 1 on average per day.

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[MadMoney]

That looks great!

[Norseman]

That looks great!

Thx, but all the problems are not over yet.
Just found out today that water will enter the base, hence there is drain holes in the aft part of the gasket. (Talked to the factory)
I better use heat shrink on the connectors in that case, tried to seal the conduit where the connectors are hidden, but not sure it worked.
Having a canvas cover made to protect the light from the elements 99% of the time, but still, need to make the whole thing bullet proof so I can sleep at night.

[Norseman]

Canvas cover just arrived, nice design with a little skirt that goes all the way down to the top surface.

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[Jkraft]

Dag, I would like to order a light cover too. Think your person would make me one?

[Norseman]

Dag, I would like to order a light cover too. Think your person would make me one?

Sure, I will ask her.

[Jkraft]

Thanks man!

[Norseman]

Thanks man!

What color sunbrella do you want?

[Norseman]

Had to find a way to plug this hole and make the conduit water proof: Turns out water will enter the light housing and drain down (but the lens is sealed)
Tried to heat shrink the connectors which is 2” below the opening, then insert a rubber cone with a hole for the cable and a slit to get the cable in the hole.
Did not work, the heat shrink made the contraption too stiff to go through the 90 bend of the conduit.
Removed the heat shrink and instead soaked the connectors with dielectric grease/silicone, pushed the plug down and sealed the top with silicone sealant.
Hoping it will be sufficient, time will tell..