Tools that work & Etc.

[Commander 147]

Ebb

When I did mine I was lucky because my router bit reached back far enough to include the screws. I will not be so lucky on the thru deck fitting for the chain to go into the chain locker. Some of those holes are 3/8" from the edge of the main hole of the fitting and some are 1/2" (on the ends of the oval) from the main hole. So for that fitting I will probably do as follows.

1.) Drill the main hole thru the deck

2.) Drill thru the top skin only for the oversized screw holes around the perimeter.

3.) Use a forstener bit to clean out the balsa down to the top of the bottom skin at the oversized screw hole locations.

4.) Route out the balsa around the perimeter of the large hole with the slot cutter.

5.) Tape the bottom of the large hole so when I pack in the mishmash into the edge of the large hole ( I used a cardboard tube on the one I already did covered with celophane tape to pack in from the edge) it does not drop below.

6.) Pack the mishmash into the edge of the large hole and the oversized screw holes.

7.) Allow to cure and sand the top flat and clean up excess in the center hole.

8.) Put my thru deck fitting in place and drill the screw holes thru the deck.

9.) Counter sink the screw holes and put a chamfer on the edge of the large hole to create caulk rings around the openings.

So pretty much the same method you listed with a few minor deviations. I am curious why you would use clear resin in your screw holes. Am I missing something here? I know I still have a lot to learn when it comes to working with epoxy.