Rebedding grab rails

I knew I would be learning on the job so to speak. Fixing things and maintaining my boat that is. Other than replacing an impeller, this was the first real project. 

The concept of mirror image grab rails on topside and interior ceiling seems straightforward. Thru bolts joining them, some type of sealant keeping the water out. But this isn't an easy job. 

First, drill out the existing bungs to get at the bolts from both sides. Did I mention this job has been done a few times on a 1977 boat? So there are two or even three bungs at each attach point because they've had to be repositioned. So drilling some bungs leads to nothing. Others to the actual bolt. 

Drilling produced a lot of debris. And wouldn't you know it, that's when the wife visits to note the cushion backs getting dirty (I was smart enough to move her cushion bottoms to the V berth). 

A few hours I've got the bolts out, rails off, cleaned up with acetone. And taped the bottoms of the holes in the topside  do I can add epoxy into the space between the two layers of fiberglass. The balsa core I dig out a bit and time has helped with that part. 

The epoxy mixing process is one I think you learn with experience. Well the pre measured pumps are good except the hardener one didn't work right. And then curing seemed to take awhile then happen at once. So I had to syringe in liquid epoxy to the voids. It took a lot which should've been the warning. But no. The warning was epoxy dripping in through the window seams. 

Cleaned up, then on to taping the rebedding surface for the 4200 sealant. Only, lining up the rails, and using pressure to get the bolts to close once again required a hand from a kind volunteer. 

Finally closed up, removed tape. Then took my daughter to sushi then 31 Flavors. 

Next up, the 18 new bungs, sanding, and revarnishing the rails. Fun times this boat ownership. ;)