New Roswell Aviator Pro on 96 Sport - fibreglass reinforcement

[Canuck-Surfer]

I will be installing my new Aviator Pro (with flush OEM mounts) to my 96 Sport this week or next. Does anyone have any input if I should try to reinforce the fibreglass under the cap at the mount location?

Jeff...you’ve done a few restorations on this era boat...any opinion?


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[NautiqueJeff]

As long as your deck thickness is 5/8" or greater, no reinforcement is necessary.

[Stevemo14]

I put 1/2” HDPE under mine. I did as the instructions said, and used short strand fiberglass filler.

To get the shape I used wadded you foil to make a sort of mold, then I just traced it out on the HDPE then used the jig saw to cut it.

I spread the filler on the top part of the HDPE, set it in place, slide it back and forth a few times, then put a few wood screws in from the top.

Mine is rock solid!!


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[Canuck-Surfer]

I put 1/2” HDPE under mine. I did as the instructions said, and used short strand fiberglass filler.

To get the shape I used wadded you foil to make a sort of mold, then I just traced it out on the HDPE then used the jig saw to cut it.

I spread the filler on the top part of the HDPE, set it in place, slide it back and forth a few times, then put a few wood screws in from the top.

Mine is rock solid!!


Sent from my iPhone using Tapatalk

Great method. Where did you get the HDPE and how thick?

[Spud]

When installing Aviators on any of our customer boats we always use some aluminium angle pre drilled then covered with Sika on the top side of the angle to bond to the bottom of the deck. This way its light weight provides a larger braced area and the aluminium is resistant to the elements. We have never had any issues doing it this way.

[Canuck-Surfer]

When installing Aviators on any of our customer boats we always use some aluminium angle pre drilled then covered with Sika on the top side of the angle to bond to the bottom of the deck. This way its light weight provides a larger braced area and the aluminium is resistant to the elements. We have never had any issues doing it this way.

I've measured my top cap thickness through the cupholder hole that is nearby. Its 0.386" using a digital calliper, so way less than the required 5/8" min. Would this solution work for thin glass? And just to clarify some of your vocab, "angled aluminium" like a span of L-shaped aluminium? And what kind of Sika, they make many adhesive products.

[Spud]

We use Sika 291. Yes L shaped aluminium to "span the entire mounting area/surface. The L shaped aluminium combined with the bonding of the 291 Sika has never let us down on any installation..

[Canuck-Surfer]

We use Sika 291. Yes L shaped aluminium to "span the entire mounting area/surface. The L shaped aluminium combined with the bonding of the 291 Sika has never let us down on any installation..

Amazing. This sounds so much better than making glass peanut butter. I guess I just need to find an L-angle bar wide enough to accommodate the Aviator Pro OEM mount bolt pattern. Would Home Depot carry this? How thick should the the aluminium be?

[Spud]

3″ x 3″ x 1/4″ aluminium angle
3″ x 3″ x 3/8″ aluminium angle

[Stevemo14]

Great method. Where did you get the HDPE and how thick?

I got it off of amazon, it was like $20.00 1/2" thick. i think the piece i got was 12" x 24"