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Restoring Rails - '70 Katama
RGPatterson	#1  Posted on 01/26/12 - 7:32 PM
Member Personal Page Posts: 13 Comments: 1 Joined: 11/30/11	Has anyone had this experience? I'm restoring the railing on my '70 Katama. The stainless rails are in good condition, but the 90 degree fittings are badly corroded. In fact, I had a cut them off. Now with the new (after market) 90 degree tees that I purchased at Specialty Marine, I'm not able to "slide" them on, as they will not slide over/past the bends of the rail. The originals were apparently riveted on at the factory prior to the rails been shaped/bent to specifications. Any thoughts? Thanks
bmw90w	#2  Posted on 01/26/12 - 8:20 PM
Member Personal Page Posts: 328 Comments: 1 Joined: 09/08/09	You could order original fittings from Sue at Twin Cities Marine. Whaler might have come out with stainless replacements, but I am not sure. I know they came out with a stainless bow light replacement for my montauk. If not you can order those from her or have any remaining ones of yours chrome plated. She is the best place to get oem whaler parts. Those fittings aren't cheap though. 1984 Montauk
Finnegan	#3  Posted on 01/26/12 - 10:18 PM
Member Posts: 1926 Comments: 16 Joined: 05/02/08	You are correct - Whaler installed the fittings onto the rails before they were bent. The accepted solution is to cut the original rail at the center point of the fitting location. Then the "tee" slides on, and then you install a "hot dog" 3/4" O.D. section of rail into the interior of the rail as a sleeve. You can use either ss or aluminum rail section, about 6" to 8" long. Once the fitting is tightened to the rail halves, it will be as strong as if it was never cut. A quick description of all of this is to use an interior splicing sleeve. It seems really amazing, but back in those days Whaler used chrome plated zamak (zinc) rail fittings, not chrome plated brass or ss.
Gamalot	#4  Posted on 01/27/12 - 5:23 AM
Member Personal Page Posts: 1086 Comments: 3 Joined: 06/21/10	I did mine the way Finnigan described but someone here mentioned a two piece T that seemed like a decent alternative to avoid cutting the tubes. A search of rails or possibly rail fittings might get you to the photo.
bmw90w	#5  Posted on 01/27/12 - 8:46 AM
Member Personal Page Posts: 328 Comments: 1 Joined: 09/08/09	I didn't think about the cutting part, that doesn't sound like fun! Maybe the fittings were different on that boat, becase my montauk has chrome plated brass fittings. Sue was telling me Whaler's chrome plating process was second to none though. 1984 Montauk
Bob Younger	#6  Posted on 01/27/12 - 10:57 AM
Member Personal Page Posts: 136 Comments: 2 Joined: 06/22/07	Had the same deal on my 63 Eastport a few years back. Cut the rail where one of the Tees was so I could slide the other one on (there are two tees on the rail). Didn't use an interior sleeve. When all mounted back you could not tell the difference in appearance or strength. Takes minutes.
Joe Kriz	#7  Posted on 01/27/12 - 11:16 AM
Site Owner Personal Page Personal Album Photo Albums Project Albums Posts: 11447 Comments: 452 Joined: 03/18/05	I would suggest using a "Hot Dog"...... Do a search for Hot Dog or Hotdog. Here is one I found. http://www.whalercentral.com/forum/vi...;pid=80868 I used the hotdog on my side rails when I cut them down. http://www.whalercentral.com/articles...icle_id=90
RGPatterson	#8  Posted on 01/29/12 - 6:02 PM
Member Personal Page Posts: 13 Comments: 1 Joined: 11/30/11	Much thanks to all for the suggestions. I have decided to cut the railings, re-fit with sleeves (hot dogs).
blindeman	#9  Posted on 01/31/12 - 5:26 PM
Member Personal Page Posts: 182 Comments: 2 Joined: 07/28/08	RG -- I had the same problem. Bought replacements from Specialty Marine, cut and slid the pieces in and screwed it all together and reinstalled. One season later, they are still holding and firm like new -- and I didn't use a hot dog. I should have. Just didn't. If they loosen up later on, I can always add. But, once done, you'll be the only one who knows you had to cut the rails. They look good as new when done. Good luck!!! Bruce Lindeman 1992 Sport 13
RGPatterson	#10  Posted on 01/31/12 - 8:39 PM
Member Personal Page Posts: 13 Comments: 1 Joined: 11/30/11	Thanks Bruce.