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Insert style rubrail
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There are 2 types of rubrails. One kind is a track with a slot that gets an
insert. The other is a track that gets a cover over it. The tracks are screwed to the boat.
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Cover style rubrail by Tessilmare
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Tortuguita has rubrails down the sides and around the swim
platforms. Both were in terrible shape
and were removed for the gelcoat spraying.
The rubrails that are on the sides have an aluminum track with a plastic
insert. The aluminum was deteriorated,
the caulk had failed and dirt and algae were living behind the insert. We
replaced these with Vetus EHARO60.
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Original swim platform rubrail
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Old rubrail removed from groove
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The swim platform rubrails were an extruded white rubber that
was screwed to the hull through a slot down the center which was then caulked
to keep water out. This is kind of a
hybrid design. These were also in
terrible condition. I researched all options
and unless I wanted to have 500’ custom made, I could not find an easy option.
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New rubrail has to fit in this groove
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The big problem finding a replacement rubrail is that it has
to fit into a recessed groove that runs around the perimeter.
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Rubrail on LUNA. RADIAL 30
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Lou on LUNA turned me on to the Tessilmare
RADIAL rubrail but the one he used was a little smallish looking (30mm) but it
did mount inside the groove easily.
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Mounting and thermoforming the track
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Well, of course I wanted bigger and didn’t care how hard it
was to install so, I bought a sample of the Tessilmare RADIAL 60mm and came up with a plan, sort
of. Nothing ever goes as planned.
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Bend the cover to get it on the track
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The rubrail mounts on a track by bending the cover and
feeding it onto the track. It’s a neat
design and there are many videos on youtube of installations on flat surfaces. The problem with installing it into a groove
is that the cover spreads out when bending which keeps it from fitting onto the
frame.
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Mount and trim the cover
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The first part was to mount and screw the track to the
groove so that the cover would fill the groove as much as possible. I actually installed the rubrail upside-down
so that the long edge runs around the upper corner of the swim platform to hide
the gap at the top. The track had to be
thermoformed with a heat gun and screwed in place so that the finished product
wouldn’t have gaps.
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Hold the bottom in the groove and pull the top back to access the screw
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Now the fun part was to remove the track and mount the cover
on it.
Then the assembled unit had to be
caulked and screwed into the prior drilled holes.
Some thermoforming was needed on the cover
around the compound corners.
After the caulk dried, the edges were taped and caulked.
Each hull took 8 long days to complete with the only real
unexpected issue was that the track, being black plastic, expanded 6mm in the
heat of the day. This really caused
problems getting the screws back in the correct place during the final
remounting. Nobody said it would be
easy. Especially me.
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Finished product
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