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My 2021 has stern cleats (on the gunnels behind the console) and a single bow cleat but no cleats on the gunnels forward of the console. I want to add a pair forward. The boat has factory installed upper forward and lower forward rails. I have not yet done all the measurements but presume the rails are screwed to the phenolic reinforcements indicated on the reinforcement diagram supplied in the manual. The Montuk150 reinforcements are only two types, plywood or phenolic.
The manual lists the load characteristics of:
plywood (light equipment weight) attach with self-tapping screws
phenolic (heavy equipment weight) attach by drilling and tapping, this would be my preference for mounting
Proper machine screw mounting requires drilling with a Number drill and then tapping (#7 drill for 1/4 -20 tap).
My question is: since the holes are blind I wonder if I would need a bottom tap to develop threads all the way to the bottom of the holes or will I encounter the internal foam core and the tapping can be done using a regular tap and penetrating into the core?
The manual lists the thickness of the reinforcements, 1/2 inch plywood and 3/8 inch phenolic. No drill depths are given so I propose to estimate the fiberglass and gel coat thickness is 1/8 inch so I must add this to the thickness go get the proper hole depth. Does this seem right?
Finally, if I have to use the plywood reinforcements how strong will the cleats be? I ordered two open base stainless 8 inch cleats, Hershoff style that closely match the style and size of the factory installed cleats.
That is all the thinking I will do and will use a proper sealant not an adhesive on the screws and the bedding.
There are two issues that hound me here. 1-I try to avoid ever drilling into a boat and 2 I don't want anything I attach to ever come off unless I want to remove it. Cleats can experience major forces when unexpected events occur so I worry about that.
In thinking about failure though as long as the pull on the cleat is horizontal it should be able withstand large loads which would tend to "tip it over" rather than pull it up.
