Making the aft cabin cover permanent
22 April 2019
Jim Ulmer

Cabo Rico decide to raise the deck of the aft cabin on the later model Tiburons. What they did was basically cut a hole in the aft deck and add a raised section over the hole. This was secured with 5200 and screws and the joint was covered with teak trim.
This was a fast way to complete the alteration and it does provide a nice additional head room in the cabin. And it lasted for over 40 yrs but there where signs that the seal was now leaking.
I decide that I need to make this a solid part of the deck. It took me all day to cut the cover free and then all the next day to remove the sealant and prep for glue.
I was working alone so I had to get this right or the epoxy would cure before I was able to get the cover in place and screwed down.
Mixed up 12oz of epoxy added 12 heaping tablespoons of West 404 and 15 tablespoons of West 406 to make a strong and thick glue.
I loaded into a West caulk tube. I had first primed both surfaces with epoxy resin and then laid a 1/2" bead of the thickened epoxy all the way around the joint. I lowered the cover quickly as the epoxy was starting to cure. I quickly went around the outside seam to put in screws to clamp the joint. It worked very well but I was worn out.
I will grind the outside seam and but two or three layers of glass over the seam then fare and paint. No more leaking!
More pictures in the refit gallery.