Rebuilding Sunpad

[GeorgeKohler]

A friend of ours, Bill, has a 2005 Larson with a big sunpad over the engine compartment. It has rotted out around the hinges and has come loose, and new screws have only put off the inevitable until now.

Here's the underside of the sunpad:

And here's a close-up of the bolt holes (using t nuts):

We got some 3/4" marine plywood and made a whole new deck based on the old one. We're on the 4th coat of Minwax Helmsman Spar Urethane, and plan on one more before trying to reattach the foam and vinyl. We have new hinges and have sunk new t-nuts into the new sunpad.

Any hints, tips, tricks before we go any further?

 

[Michael Clemensen]

Monel staples and SS screws.

 

[jmas]

George, Any sign of Termites in old Sunpad? The small holes look suspicious.

 

[GeorgeKohler]

No, no termites. The small holes are my attempt of a quick repair. I welded some stainless steel to the old existing hinges
in an attempt to get some bolts further into the center of the pad. Worked for a couple of years.

 

[GeorgeKohler]

Other small holes are from the staples holding the vinyl.