What to do with all those old bolt holes? Since the new teak rails will be manufactured in the shoppe-- complete with countersink holes drilled 10 inches on center, it will be difficult to get the holes to line up perfectly. As a result we are going to fill each hole on on the hull deck joint flange with structural putty ( an epoxy mixture with micro-fibers). When the new rails are ready for installation we will match drill the hull deck joint and not be obsessively concerned with mis-matching holes.
We have also decided to use SS cap bolts without countersinks. Some wood experts believe that using countersinks build in a weakness for splitting the wood since the bolt is in the shape of a wedge. I don't have enough experience to agree or disagree, however, while removing the rails they split quiet nicely through the holes. In addition, on the starboard side the damaged area gave up through the bolt holes in several places as well.
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