Did something semi-stupid!

Hey guys/gals, figured I'd update you on my progress with this project.

Cut a 5" diameter piece of wood, cut a 1-1/2" hole in center for mount. Sealed it with epoxy. Got to the boat marked the through holes with the mount; put some 5200 on it and put it all together.

Perfect, still has a little flex but no more than the 48DA on our dock. It looks good and Admiral is happy.

We were running at about 3700rpm, 25+ mph, and most of the wind blows over the flag anyway so there is not that much stress on it. I was quite surprised.

Anyway, thank you all for your suggestions and tips. CSR and the folks on it rock!!!!
 
Anyone have any tips on how to drill this 1.5" angled hole for the flag pole? i.e., what kind of drill bit/hole saw did you use? What kind, if any jig did you use/make?
 
MarysPool said:
Anyone have any tips on how to drill this 1.5" angled hole for the flag pole? i.e., what kind of drill bit/hole saw did you use? What kind, if any jig did you use/make?
Click to expand...

I just put the hole saw to it and drilled. I think I started with the center drill bit contacting and penetrating the transom to hold the saw in place, then I tilted it to the correct angle as the outer edge began to grind. Don't wait too long to tilt it - the edges of the hole saw will not move the hole like a drill bit will.

Be careful not to let the hole saw take off like a dragster across your gel coat. As long as you don't get out of control, there is a little room for error as the flange around the flag pole base will cover any small gaps (if it's like mine). You may need to drill a slightly larger hole to help account for the angle, but make sure you don't mess up your screw holes. Don't start too small, it's really hard to enlarge it, unless you just drill it slightly angled, then modify it to an oval using a rasp (is that the right tool?).
 
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Covering the surrounding area with a couple of layers of masking tape will prevent minor scrapes and keep the area at the cut clean.

If the hole saw does get away from you, it is not the end of the world. Gouges can be easily DIY fixed with the gelcoat kit from Spectrum color.

Henry
 
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