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I just took my pedestle seat screws out and found that there was no sealant used when they were installed. In fact they didnt even clean the debris from drilling before they mounted the seats. This is a very moisture prone area. Bayliner quality install job for sure.
I suspect Whaler was trying to save time and money when installing screws. I've noticed that my deck screws loosen over time. It doesn't appear any sealant was used...I picked up a (3) pack of syringes from the local the marine store and injected 5200 into each screw hole then replaced the screw. Hopefully this will seal the deck properly and hold the screw in place....
Tom - I had a similar problem on my 1986, which went unattended too long by the previous owner and ended up ruining my deck.
I recommend that you use 3M 4200 and NOT 5200. 5200 is designed to be a structural adhesive and this is an improper use of the product. 4200 is more like a solid caulk and will give you a better result.
If your screws are stripping, or if you notice any sign of water intrusion into the core of the fuel tank cover, you should remove, overdrill the hole to about 1/8 inch, let dry (using a cotton cloth may help wick moisture out of the hole) and then fill the hole with Marine-Tex and re-drill a new hole for your chairs.
Mike - I'm going to guess that the edges of your fuel tank cover is a little like mine was, with the screw heads pulling through the cover surface - good solid grip to the hull underneath, but beginning to lose grip on the cover itself.
First, let's talk about "what lies beneath" your tank cover. IN the hull, beneath the fuel tank cover is a thin strip of wood under the glass. This provides those 40-some screws with purchase to the hull. You may also notice six very large screws under your console which are affixed to two very large structural timbers (who said no wood in a Whaler hull?) which run alongside the fuel tank.
If your deck screws are holding strong to the underlying wood, you're in good shape. I'd remove all 40-some screws and overdrill the holes, filling them "almost" to the top with Marine-Tex. Add gelcoat to the top and sand smooth. Re-drill the holes and insert the screws.
My guess is that if your deck is that bad though, that you have some rot in the fuel tank cover core. I'd look into addressing that problem as well before it spreads and destroys the structural integrity of the whole deck. These are not inexpensive to replace and are very time-intensive to fully repair or re-core. Fix small problems now before they graduate with masters of disaster and rain down their post-graduate fury on you, the unsuspecting owner.
Thank you for the good ideas! My 91 25 OR is in good shape and the deck is solid, no flex. Im lucky because I have a Stamoid cover so Im able to keep it covered when not in use and make repairs out of the weather. I'm sure there are is some rot under there somewhere just based on the age of the boat. The boating/fishing season is starting here in Maryland now so I'll address the deck next winter. Thanks, Mike.
I suggest filling the holes with Marine-tex and re-drilling. The screws for the chairs go clean thru the deck and into the hull, at least 5 of mine did. There is some caulking, but not a lot and I am sure these were one source of water into my hull.
