Drilling holes in your boat

[Ron Barwick]

I'm going to install some new electronics in my boat and don't have any problems with the electrical part. But, what's the best way to make the larger holes, one is 1" in diam. and the other is 1/2" without chipping or cracking the gelcoat?
These holes will be in the console. Regular hole saws you use in a drill look like they could do some damage.
The dash in bass boat is teak, I had no problems there. This Key West is all glass.
RB

[Capt Cefus]

Well, here's one opinion, and I never had any problems.   BUT, when it comes to drilling holes in a perfectly good boat... especially the hull... to me that's like jumping out of a perfectly good airplane      

Knowing that you're drilling in the console, here's what I've done in the past.

Take some heavy duty BLUE masking tape and tape over the area you're gonna drill the hole.   Mark your hole area on the masking tape.   I've drilled holes over 2" for rod holders this way.   Mark the center where the drill bit will start and make a small pilot hole with an 1/8" bit or smaller.   Then chuck up the hole saw.   I have always had the good fortune to have sharp, fine toothed hole saws.   I don't know what an electrician's hole saw would do with the coarse teeth, and I'd bet a spade bit would reek havoc on your gel coat.    But I rev it up and let the saw do the cutting.  If I'm installing rod holders, then I'll go in at the angle the holder will be resting.

Remove the tape and you should have a smooth, unmarred gelcoat surface.   I'll use the tape trick if I'm using a sabre saw for flushmounting electronics too. 

Now, with that said, I'll bet there's an even easier way and one that's guaranteed not to screw up your fiberglass.   I haven't had any problems yet, but never say never.   

[Pressure Drop]

I have done this many times with great results and no chips... Like Cefus said tape it first. I only use BLUE PAINTERS TAPE. This is the best and leaves no residue to clean up.

Just before you start the drill say a prayer to the gel coat gods and all will be fine...BLUE TAPE

[Ron Barwick]

Thanks for the replies, why didn't I think of that? That's how I cut the new counter tops for the kitchen, using masking tape so they wouldn't chip.
To be on the safe side, I called a freind who just happens to be the hull design engineer for Century Boats. He told me the same thing you guys did! I thanked him, and just before he hung-up he says, "make sure you use blue tape".
I guess Capt K and Capt Cefus know what they are talking about.
RB

[coachb]

Oh well, there goes the site. New hat sizes for them.

[Tare]