Deck Grabrail Repair - 2007

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This spring we noticed we had a loose deck grabrail.  We had not tightened these before so we had to figure out how to do it.    Before we began the project I posted the question on the Pearson message board and got some good tips.  The message board continues to be a great place for information.  Here is what we learned.		    
 


The grabrail.

 

    

 

First, we realized that the deck grabrail is bolted into the interior cabin grabrail.  So, we had to decide which side to drill out the plug.  On the deck? Or inside?  Turns out the screw heads are on the interior side (Actually, we knew this ahead of time because of the message board!).

 

    

When you drill out the plug use a small drill to make a hole in the center of the plug and then use a small screw driver or chisel to pop the plug out.  This avoids damaging the 'hole' into which the plug fits.


Note the concentration needed to do the job at a high level.

 

    

Kelsey is making sure the hole is all cleaned.

 

    

When you get each screw out it is important to label them as each seems to be a different length.  Also note the correct placement of the rail.  The nuts are epoxied in but one of them came loose and that did complicate matters.

 

One Pearson owner drilled out the core in each hole, filled it with epoxy and then re-drilled so as to protect the core from future water intrusion.


Wow! Just an extraordinary picture...

 

    

Here is a view of a screw head.  The nuts are under the plugs in the deck rails.


Kelsey lowering the rail.

 

    

Kelsey is removing the grabrail.


Sanded but pre-varnish.

 

    

Once unscrewed we removed the deck grabrail and cleaned the deck area and re-caulked the holes.  We then tightened the rails back together.  

West Marine sells teak plugs.  We used 3/8"plugs for the interior grab rails.  We sanded the plugs until level with the rail and then re-varnished the rail with a satin finish varnish.

According to a Pearson owner the screws are 10-32 and range from 4.5 to 5 inches.
     

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