Sundeck Corner Trim Elbows

[Wayne162]

Following the loss of my port side sundeck panel, corner, and port aft panel compliments of Hurricane Matthew I am replacing the lost parts. Panels are not as much of an issue as the corners. I am in the process of using the starboard aluminum cast corner as a pattern to re-engineer it to poly-carbonate and then a mirror image made to fit the missing port side as well as a new one for the starboard corner. Carver does not make these parts any longer for the 405 and maintains that they are not available.

I originally hail from New Jersey along the shore and in the middle of many boat manufactures such as Ocean, Egg Harbor, & Viking to name a few. I'm working with a plastics machining & fabrication company in NJ to make replacement corners with a UV inhibitor for sun & saltwater use on my boat. Once we figure out the best way to make new corners, I will have them made and provide a resource to the forum for others in need of replacements.

Attached is a photo of my remaining corner.

[mjk1040]

Wayne good luck. Our marina neighbor just had his '86 36' aft cabin transformed from canvas skirting to hard panels like your 405, I don't recall now how the corners were done, if I get to the marina soon I'll look cause its in heated storage. He had the work done here locally in NY around the Syracuse area. Mike

[tomschauer]

Since you have to replace the "flat" panels anyway, how about extending them and making a square corner? You could use some aluminum angle inside and out, aluminum rivets through all three layers, probably tougher than new.

[Wayne162]

Thanks all, I want to maintain the rounded corners of original manufacture rather than square it off. It's my belief that the plastic nuts that held the original panel failed and allowed the panel to come free from the mounting rail. A previous owner used some stainless nuts on the other side and it survived.

[dsolo]

Wayne162,
I would look at extruding companies who offer a multitude of extruded profiles and materials to accommodate our marine environment. Google "plastic corner extrusions", you should get a large selection of companies with catalogs showing a large selection of profiles. Determine your corner radius dimension and mating material dimension. Companies can help search for profiles and select the material and provide material shades. You could come very close with a profile that could work. Minimum qualities could prohibit cost justification? But tooling and machining cost on a custom is very expensive also. Hope this helps Dan

[Wayne162]

Thanks Dan.

[rkrumm]

How about replacing the starboard vertical plastic panel that slides into the corner piece referenced in this string? Any leads or ideas? Mine broke off about two feet from the front of the panel during a recent wind storm. Not sure if some one still makes that piece for a 1995 430 or if I need to go to a local plastics company and have it reproduced. Maybe some strong epoxy and glue it back together?

[Wayne162]

Look up McMaster Carr on line. You can buy panels and cut them yourself. Make sure the panels have a UV inhibitor.

[IdleDrifter]

Just thought I would share how I dealt with the same issue. I lost the port side corner on my 1998 Carver 355 in a storm this Winter. I took the remaining corner to a local shop that does aluminum boat repairs in my area (mostly fixing damaged pontoon boats). They said they could bend a piece of stock aluminum sheet then weld squared "S" stock to the curved sheet to form the channels. At least that is the plan. If that doesn't work then we are just going to bend a slightly oversized aluminum corner sheet and pop rivet it to the plexiglass sides (plastic pops like those used to attach the side sheets to the existing rails should be available). With either solution I plan to take both the old and new corners to a shop and have them powder coated to prevent corrosion.

[Wayne162]

I spoke with the plastics shop handling my corner issues. They plan to handle it a similar way but by planning down a 1/2 inch marine plastic sheet, bending and routing the chanel for the poly board sides. However they are still looking at all options. I also intend to attach a weatherproof lanyard so I don't loose them again.