Petep
Member
Dom, Here's what I did, I used a 60mm (2 3/8") whole saw with a good, strong, 1/2" electric drill (Milwaukee) with a T-handle (didn't want that holesaw to get away from me while cutting). I'm very lucky because my wife is great at these projects-she went into the engine room with a ruler and I knew where we wanted to place these holes so I just told her to make sure they were "up and over" so many inches so she could make sure that there would be no surprises. We measure twice and then talked about any potential surprises and even moved the center light hole down 2" from where I thought it was going to go to make sure the light back flange would fit etc. I then drilled a small pilot hole w/my cordless-figuring that I could modify my large hole from that If I didn't like where it showed up inside (modify it by 1-1/2 inch only).
Everything was fine on the pilot hole so no movement was needed. The rest is easy - Drill away!- I then mixed up some West system and put it around the hole incase there were any voids in layout to prevent de-lam. Remember, this is important- My boat has no wood core! This is a solid layup- I know this and I still called SR to Confirm w/the HIN # of my boat. I also used my palm sander and knocked down all the bottom paint around the hole to make sure the "flange" of my lights will be on glass only. Tonight I just apply my Bostich (comes with my lights) Sealant and complete my install. I am going with 3 lights, however, I think I will be adding 2 more at a later date and am wiring as such with a bus terminal to isolate my wireing on each light and potential to add more in the future.
Don't ask me why I don't just add more now- These things are expensive!
Everything was fine on the pilot hole so no movement was needed. The rest is easy - Drill away!- I then mixed up some West system and put it around the hole incase there were any voids in layout to prevent de-lam. Remember, this is important- My boat has no wood core! This is a solid layup- I know this and I still called SR to Confirm w/the HIN # of my boat. I also used my palm sander and knocked down all the bottom paint around the hole to make sure the "flange" of my lights will be on glass only. Tonight I just apply my Bostich (comes with my lights) Sealant and complete my install. I am going with 3 lights, however, I think I will be adding 2 more at a later date and am wiring as such with a bus terminal to isolate my wireing on each light and potential to add more in the future.
Don't ask me why I don't just add more now- These things are expensive!