Found another water leak in my 260DA

I saw your update today. In your initial post you indicated the gap was 1/2", but from the photo it doesn't look that bad, maybe half of that.
While Plexus is great stuff, if the dealer pries the joint open enough to get a heavy bead of 5200 in there, and then completely refastens the joint properly and pulls it together tight, you won't have any issues. 5200 is a serious enough adhesive- it'll rip apart the fibergalss before the bond will fail.
 
I picked up the boat today. Looks great, just hope the fix is final. From the inside of the bilge area, I can see where the 5200 oozed up in the joint between the hulls.

Now to haul her back north to salvage what I can of the New England boating season before bringing her back to FL for the winter.
 
Lazy Daze said:
:smt038:grin:

Have a safe trip.
Click to expand...

Thanks. I hauled for 16 hours today. 3 of which were in stopped traffic on I95 in SC. Made it into NC. Contemplating a haul home to have it sit in the driveway for the weekend, vs. heading out to the Great Lakes tomorrow from here instead. Just gotta get a weekend on the water somewhere...
 
16 hours on the road?!?! I think the choice is obvious as to where you should go today! Go boating!!!!! Try a new place! :smt001
 
Arrived late last night, another 14 hour day hauling. We are in Alexandria Bay, NY in the Thousand Islands. Headed out to launch now and spend the weekend on the water, away from Bill.:thumbsup::thumbsup::thumbsup:
 
ChuckW said:
Arrived late last night, another 14 hour day hauling. We are in Alexandria Bay, NY in the Thousand Islands. Headed out to launch now and spend the weekend on the water, away from Bill.:thumbsup::thumbsup::thumbsup:
Click to expand...

Have a blast man you deserve it.
We're leaving within the hour for an overnighter.
 
What a magnificent day here in Alex Bay!!!!! Perfect temperature, perfect humidity level (not too much), and water is awesome. The water is so clear here this time of year.

BTW - I ran the boat hard today. 6 aboard, tubing, WOT, taking on big swells. Guess what? This is the first time in a long time, that after such a work out my bilge is bone dry. Not a drop, nothing, nada! Psyched :smt038:smt038:smt038
 
Lazy Daze said:
It's certainly not a common thing. Sorry to hear that you're having this problem, Chuck.

A number of years ago, I read a newspaper story about a Bayliner where the top deck actually separated from the hull while it was being used! It flew off like a shoe box lid! I don't think you'll have that problem, though:smt101
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What paper was that, I can't see how it could come off like a shoe box. Sounds a little strange to me.
 
ChuckW said:
Well, I've been struggling with finding the source of a large amount of water leaking into my bilge every time I go out lately. Last time out, I noticed things were very wet around the hoses to the through hulls on either side in the bilge. So back on the trailer here in the yard I went searching for the source with a hose. To my shock, the hull joint at the rub rail has pulled apart at the aft quarter on both sides. Put the hose to it and water gushes up in and over the hull into the bilge. Generally in the area over the through hulls. In order to see the gap, you have to get low and look up. Sure enough the top side is flapping loose against the bottom hull.

Shortly after taking delivery 2-1/2 years ago on this boat I had the same issue on a 10' stretch on the forward port side under and forward of the port windows.

Now it's in about a 4' stretch on each side aft. What a pain in the but :smt021

This better get covered by the Passport extended warranty. But why can't these joints hold up?

Can trailering the boat be a cause? In my mind it shouldn't matter. These things should hold like a rock!!!!:smt013:smt013:smt013:smt013

It's hard to see, but in the attached picture (between the red lines) the rub rail and top side is pulled away about a 1/2" from the hull.
attachment.php


UPDATE: 6/29/09 - Dealer Inspection.
http://clubsearay.com/forum/showthread.php?p=238065#post238065

UPDATE: 7/9/09 - Dealer will dismantle and inspect the joint on 7/31/09 when we finish vacation. Then I will know more. The dealer is even airing the expectation on my part that SR may want this back at a plant for repairs. That would be interesting...

UPDATE: 8/1/09 - Yesterday she went into service and they took off the rub rail to investigate the problem. It didn't take long, the problem was obvious. According to the tech, many of the screws used to fasten the hull joint together were of a smaller size than most, too small for the holes bored, and none of them had been put in with sealant. So the screws have let go, many stripped out of their hole, some just worked loose. The dealer is now sending the info and a proposed fix off to SR for approval. The dealer wants to rebore the holes, use the correct larger screws, install them with sealant and put a bead of 5200 in between. We'll see what SR counters with. They estimate 20 hours of labor to redo this correctly.

Note that the spacing between screws is about every 12" for the initial hull to hull fastening. Then when the rubber piece of the rub rail is screwed on, that is done at a 12" spacing on the 6" offset from the first set of screws to yield a 6" spacing for fastening the hull joint. Then the stainless piece of the rail is added with smaller screws. But if you don't use the correct size screw for the hole you bored which is long enough to penetrate and don't use sealant to hold the screw in, this happens. Shame on SR for what appears to be a total lack of quality control on this process. :smt021 BTW - my serial number on the hull begins with SERR, which denotes the Riverview, TN plant as to where the boat was built.

Some pics;

Where the screws have let go, the caulking has let go as well, allowing water to splash up between and into the boat.
attachment.php



Screw working it's way out.
attachment.php



Loose screws and a complete separation of the joint.
attachment.php


UPDATE: 8/5/09
SR has approved the dealer's plan to fix. Can't wait to get her back in the water.

FINAL UPDATE: 8/19/09
I picked up the boat today. Looks great, just hope the fix is final. From the inside of the bilge area, I can see where the 5200 oozed up in the joint between the hulls.
Click to expand...
Hi Chuck,

I have been talking on the forums about the problems I have been having with My 260DA. It looks exactly the same problem you have had with the Gunnels also I have noticed the Serial No also begins with SERR i wonder if this problem is confined to the one factory.

Regards

Dan
 
ChuckW said:
I've updated the OP. The boat will be opened up on 7/31/09.

When talking with the service manager, he had asked about my serial number to know where the boat was made. Turns out mine was done at Riverview, but he did say that Arizona's plant had some issues he's seen with hulls aligning and not staying together like mine is.

For what it's worth, I'd suggest all 05-08 260DA owner's carefully inspect the joint for any possible issues like I'm seeing.
Click to expand...

danward12 said:
Hi Chuck,

I have been talking on the forums about the problems I have been having with My 260DA. It looks exactly the same problem you have had with the Gunnels also I have noticed the Serial No also begins with SERR i wonder if this problem is confined to the one factory.

Regards

Dan
Click to expand...

I included a quoted post from above, where the service manager had heard of this happening with the plant in AZ as well. I don't have anything more than that. Perhaps others that were having this issue can post their first 4 letters of their serial num, too.
 
Chuck:

Thought you might be interested in my trip report to Bimini where I found out I have the same issue you had with the rub rail gap taking on water. My 260 goes in the shop tomorrow....

This water leak caused quite a bit of fun for us in the gulf stream.

Kendall
 
Wow, sorry to hear that. Glad you came out of it OK. Make sure they inspect every inch!

Cheers,
 
Lazy Daze said:
It's certainly not a common thing. Sorry to hear that you're having this problem, Chuck.

A number of years ago, I read a newspaper story about a Bayliner where the top deck actually separated from the hull while it was being used! It flew off like a shoe box lid! I don't think you'll have that problem, though:smt101
Click to expand...

Actually I had the same exact issue with my boat. I fixed it last fall and have not had achancr to take my boat out yet. Hopefully this issue will not lead to bigger problems in the future.
 
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