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Wall thickness of the metal tubing can vary - which of course affects the ID. Your boat might have the ticker wall thickness? Taco Metals is a big supplier for tubing - I'm not sure if they have fittings, though.

Fair enough :)

In comparison, a screw in plate has more integrity - especially as pop-ins get older. But as far as which one keeps water out better - there's really no difference if they're maintained.

Minor point, but you don't need a washer when using something like 1/4" plate - and especially 3/8" plate. The plate IS the washer. And a C-channel (or L-channel) is another washer since it sits on the plate. Sketch... Ah, OK - I see what you're talking about, now. The "top" and "bottom"...

Oh my, those are 1/2" bolts? Holy overkill, Batman :) 1/4" is more than enough. But going bigger is never bad, either. Actually, the reason I mentioned C-channel (as opposed to box tubing) is because you can access the bolt head - meaning, you only need the bolt going through the lower...

Skunk, I saw your link to this post from that other post and your comment about plate flexing intrigued me. Here's a thought to ponder... instead of adding another plate, use two C-channel pieces of stock Al (say 1-1/2" tall). These will provide much rigidity than plate. They could be...

Oh, I didn't realize this wasn't in the bilge. If the area is not connected in any way to the bilge where gas fumes could then exist, disregard some of my comments. I think you're fine with the 15amp - that's close enough as makes no difference. Besides, that's better than going to 10amp...

Yes, that should work. Just make sure your connections are tight and won't vibrate around over time. The main goal is here is to NOT make a spark in a gas bilge :cool: Minor point... but you'll likely void any warranty by cutting the plug off. Is the charger you've decided on rated IP and...

If the Al was only corroding in areas that you can easily access, you could do the repair in those spots. But looking at your pictures, there's a siginifcant chance that there's more corrosion between the engine mounting bracket and pod. And, of course, the question is... how bad is it? On a...

No! Don't do that. An outlet, of any kind, should never be installed in a bilge of a gasoline powered boat. Any connections down there must be hardwired. Bad, bad, bad idea :) And, make sure the charger is properly rated as ignition protected, as well.

You're right - the Boothbay water area is a great area to boat around in - especially with the barrier islands. I'm just up around the corner from you in Friendship.

Maybe you want to consider adding a dodger?

Only hot water comes out of the heater - no cold water goes through the heater and then to the stbd side. Cold water lines will split before the heater. Cap or connect the c/h lines... doesn't matter, both ways will work. Do you have an OB or an I/O? There may be an extra step if I/O.

Is there any evidence of something being there? Screw holes or a snap, etc? But you could just use a strap and a snap. Easy peasy, works well, cheap and no "invention" needed

Or is that from some newer model? What does "your" setup look like? That's the important part - not so much what's newer model have as it may have changed.

So you already did this?

It's all doable - when Inrebuilt my cockpit floor, I even built a brand new hatch where the cutout for the old sterndrive engine used to be. I created a drip ledge and drained/plumbed it directly into the stbd floor drain. It works good - but not perfect - enough water on the floor all at once...

Not sure who you are referring to nor what "it /ma sis" means?

Yeah, wasn't quite sure of your existing skill set so I tried to respond on the side of caution. If this is something you're comfortable doing, do it - but as you know, expect to get socked in at times for a couple days... maybe even a week or longer. As long as you have the time and patience...

If there's a rise in the hose after it leaves the interior deck fitting, yes, that sounds like the issue. Re-route the hose and or cut some of the hose off - depends on which way would work better - you can see it better than us :) Or... since it's a 2025 - maybe your GW dealer will be able to...