Toe Rail Removal/installation

Post photos and descriptions of your ongoing projects here. No project is too big or too small.
Post Reply
lsheaf
Master Varnisher
Posts: 112
Joined: Tue Sep 10, 2019 8:41 pm
Boat Name: Stardust
Boat Type: Allied Seawind 30

Toe Rail Removal/installation

Post by lsheaf »

Hi guys,

I’m going to do my best to document the toe rail removal and installation of new toe rails.

The main purpose of removing the current aluminum toe rails is to reinforce the hull/deck joint as well as insure there are no leaks at the flange. Since the existing aluminum toe rails have also suffered from corrosion, they will be replaced with the same model rail.

Note: unlike most aluminum toe rails, these rails fasten with a carriage bolt (aka square neck bolt). The square neck, when seated into the rail, prevents the bolt from spinning when tightening the nut. This makes for a potentially easier installation.

Many different style extrusions can be found at Crest Aluminum out of Mentor, Ohio.
lsheaf
Master Varnisher
Posts: 112
Joined: Tue Sep 10, 2019 8:41 pm
Boat Name: Stardust
Boat Type: Allied Seawind 30

Re: Toe Rail Removal/installation

Post by lsheaf »

Day 1:

Remove all nuts, washers, and bolts.
Remove port and starboard toe rails.

Using a hammer, 1/2” wide chisel, 1/4” wide flathead screw driver, and a long/sturdy razor knife, I begin prying and cutting the sealant underneath the aluminum extrusion.

For those wondering, I was indeed able to prevent any bending or kinking of the metal while prying.

I found it best to start with the chisel and hammer it in about 3/4 of the way underneath the rail. Cut any sealant between the underside of the rail and the top of the flange. Then hammer in the 1/4” flathead right behind the chisel. Pull the chisel out , move down about 6”, and repeat the process.
Attachments
825FD78F-D047-4F00-83A8-AB3F867120EA.jpeg
3AF5EDBD-A668-4630-98F5-62F911692B8B.jpeg
User avatar
pmnfernando
Candidate for Boat-Obsession Medal
Posts: 329
Joined: Tue Sep 08, 2020 9:45 pm
Boat Name: Katie J
Boat Type: Van de Stadt Pioneer 9

Re: Toe Rail Removal/installation

Post by pmnfernando »

Hi

Are you glassing over that low bulwark?
lsheaf
Master Varnisher
Posts: 112
Joined: Tue Sep 10, 2019 8:41 pm
Boat Name: Stardust
Boat Type: Allied Seawind 30

Re: Toe Rail Removal/installation

Post by lsheaf »

Yes I will be fiberglassing it with 10oz 3” wide cloth tape.
lsheaf
Master Varnisher
Posts: 112
Joined: Tue Sep 10, 2019 8:41 pm
Boat Name: Stardust
Boat Type: Allied Seawind 30

Re: Toe Rail Removal/installation

Post by lsheaf »

After removing the toe rails and all of the sealant I think it may not be necessary to fiberglass over the hull/deck joint. Everything looks in tact, with a few small sections that could use some filling.

The fastest way to remove the sealant was using a grinder with a 40 grit sanding disc. I smoothed out the entire length of flange with 80 grit on a DA. The surface is now prepared for repairs or priming.

The existing port and starboard toe rail fastener holes unfortunately do not have equal starting points which means that one side will end up further aft or forward than the other.

The existing fastener holes on one side of the hull/deck joint need to be completely filled, faired, and re-drilled.

In order to ensure the holes are drilled far enough away from the hull, (if they are drilled too close, the washers/nuts will not seat flush to the underbody of the joint) I will need to glue a piece of neoprene rubber padding along the inside of the new aluminum toe rail. This will ensure the new holes are drilled at equal distances from the edge of the joint. Unfortunately I don’t have a good picture of the joint profile but maybe the sketch of the toe rail design would help.
Attachments
72B82868-C0DD-4BDB-B8A5-B846A06FD0AE.png
4000F0EB-B2EF-45D7-8585-4ABD0D711FB6.jpeg
39514E1E-CAE8-4394-903D-1EE001C597EE.jpeg
lsheaf
Master Varnisher
Posts: 112
Joined: Tue Sep 10, 2019 8:41 pm
Boat Name: Stardust
Boat Type: Allied Seawind 30

Re: Toe Rail Removal/installation

Post by lsheaf »

I began fiberglassing over the hull/deck flange on the bow (separation of the joint at the bow is supposedly common on the Allied Seawind 30 due to inadequate fastening). Since this part of the project ended up being a lot easier than I initially expected, I just fiberglassed the entire flange to ensure no further leakage.

This was done by smearing West systems 406 colloidal silica along the vertical edge of the flange and then fiberglassing over with 2 layers of 9-10 oz 3” wide tape.
Attachments
0FAA636D-CDDE-4A28-9F2C-7A94A82E4227.jpeg
EFF6BD57-A998-4A73-9B74-5D7D77D07BB7.jpeg
Last edited by lsheaf on Wed Sep 14, 2022 5:51 pm, edited 2 times in total.
lsheaf
Master Varnisher
Posts: 112
Joined: Tue Sep 10, 2019 8:41 pm
Boat Name: Stardust
Boat Type: Allied Seawind 30

Re: Toe Rail Removal/installation

Post by lsheaf »

After fiberglassing the entire flange, I prepared the flange and hull for awlgrip primer and paint.
After spraying 2 coats of 545 finish primer and 3 coats of Snow White topcoat, I was ready to prepare the new toe rails for fitting and preliminary fastening.
As mentioned in one of my previous posts, it was necessary to glue a neoprene spacer on the inside of the toe rail to ensure the bolts would go through the center of the flange (longitudinally centered). I used contact cement to glue the neoprene to the aluminum. I did some testing and found that adhesion was best when sanding the aluminum lightly with 220 grit and sanding the neoprene with 80 grit.

When the contact cement fully cured, I began dry fitting the rail.
I used the mizzen halyard to support the aft end of the rail and another line attached to the stern cleat to bend the rail inward.

Once the rail was fitted, I pulled the rail back off and began applying 5200 on the top of the hull/deck joint. (I also sanded the top of the flange so the 5200 had something to grab onto). I applied 5200 in approximately 8 foot sections at a time.

Here are some pictures
Attachments
B90CD75A-39D4-40F3-926D-B0905DFE033E.jpeg
8E54F07F-26CE-4B2D-978E-B13F4B4C6F76.jpeg
22629145-9B73-432F-937A-96D94966E9F6.jpeg
CAE8E466-4575-40AE-95ED-8F4703FE416E.jpeg
3794D438-4344-4A9C-887C-845AC399951D.jpeg
Last edited by lsheaf on Wed Sep 14, 2022 5:54 pm, edited 1 time in total.
CapnK
Site Admin
Posts: 251
Joined: Thu Aug 25, 2005 10:28 am
Location: Winyah Bay, Georgetown SC

Re: Toe Rail Removal/installation

Post by CapnK »

Looking great, Logan! The perforated AL toerail is a really good addition, and can come in handy for a number of uses mundane and otherwise. Like as an emergency lashing point to keep your spar up when the chainplate for your uppers explodes during the 70/100mph winds of a hurricane... (I'll try and find the pic I took of that rig after the storm passed. :) )

I should ask - where did you source the toerail material?
Kurt and Barque, the CrewDog.
Sundance, '71 A-30, #429
Katie Marie, Ariel #422
Melelani, Islander 36 (shoal)

sailFar.net - Small boats, Long distances...
lsheaf
Master Varnisher
Posts: 112
Joined: Tue Sep 10, 2019 8:41 pm
Boat Name: Stardust
Boat Type: Allied Seawind 30

Re: Toe Rail Removal/installation

Post by lsheaf »

Hey Kurt,
Haven’t been on here in a couple weeks.
I’m in the process of painting my decks at the moment.

But yes I love the new toe rails!
I purchased them from Crest aluminum out of Ohio.
I’d love to see the picture by the way, were you at anchor or sea when that happened?
Post Reply