Kayak Rack Installation Help

Warren,
I think that there is plenty of strength on the roof of the Tom Cat for Kayaks or inflatables. I get up on the roof, and there is slight deflection. What I have seen is that the center roof of my C Dory 25 does flex enough that I don't stand on it. I don't have any cracking on the center of the 25, but I have seen a 25 with some stress cracking in the center part. So I do not recommend more than a 150 lbs, well destributed on the roof of the 25. I cannot comment on the newer 25's (mine is a 2003 boat).
 
I emailed the factory again and got this response:

"...you are correct the area of your hard top that is outboard of the rails has ½ in. core in it."

How important is it to overdrill/undercut and fill with epoxy on the cabin top? I understand doing it below the waterline or where water will pool, but is it just as necessary on the cabin top? I have no doubt that it is the best way to make sure there is no water intrusion, but would a rubber gasket and 4200 be sufficient?

If I do end up filling them with epoxy how long would Marine Tex take to cure at 40 degrees? Can it even be used at that low of a temperature?
 
I cannot speak for the vintage C-Dorys out there, say greater than the last couple of years, but current C-Dory tops are cored as follows:
16' Angler - no core
16' Cruiser - center section has 1/2" core
19' and 22' - 1/2" core along sides (just beyond handrail) and strip along back. This is for both the standard and hightop.
25' and TomCat - 1/2" core over the full top.
23' and 26' Venture - synthetic core across full top.

So the answer to "Is the C-Dory top cored?" is not a simple answer.

Rich F.
 
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