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Ensign Sailing Forum

Deck holes in Ensign Classic
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Thanks Zeke. Nice to get the info from the horse's mouth, so to speak. I know you made several other improvements to the build as well. After sailing hull #340 for many years - a boat I also loved - I can appreciate your upgrades.

Thanks - appreciate the pics. You were busy!

Joseph, 

I built your boat and we used a closed celled Klegicell and in the high-stress area with cleats or blocks would go we used cusa board. Cusa board is like steel. Both materials will not wick water from leaking fittings as balsa did. 
There are about 12 inches of cusa from the eyebrow forward on top of the cabin where your cleats will go. 
You just need to use a good caulking like 5200 and fender washers. 

Zeke


Joseph,
 
Forgot to include pics of my cabin top during refit...
 
Cheers!

In a message dated 11/3/2021 12:13:45 PM Pacific Standard Time, ensignsailing@ensignclass.com writes:
 
Posted by: Edward M Rose on 11/3/2021 at 12:14 PM
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Joseph,
 
I own an older Ensign and drilled over-sized/filling/final-size with beveled counter sink for the cabin top hardware. I also used marine grade butyl tape pushed into the bevels. This is how I did mine...
 
Ed
Ensign #1484 
 
 

In a message dated 11/3/2021 9:44:46 AM Pacific Standard Time, ensignsailing@ensignclass.com writes:
 
Posted by: Joseph R Burke on 11/3/2021 at 9:43 AM
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I own Ensign Classic #2016 (great boat!). I believe these boats were made with closed cell foam core vs.end grain balsa. I'm planning on making substantial changes to the cabin top hardware.. Is the cabin top cored? Are there any solid areas? And what's considered best practice these days: bedding with butyl tape or overdrilling/filling/redrilling? Thanks for any info.

Joseph,
 
I own an older Ensign and drilled over-sized/filling/final-size with beveled counter sink for the cabin top hardware. I also used marine grade butyl tape pushed into the bevels. This is how I did mine...
 
Ed
Ensign #1484 
 
 

In a message dated 11/3/2021 9:44:46 AM Pacific Standard Time, ensignsailing@ensignclass.com writes:
 
Posted by: Joseph R Burke on 11/3/2021 at 9:43 AM
View/reply online
Reply to forum at ensignsailing@ensignclass.com
If this message contains inappropriate content, you can report the message online

I own Ensign Classic #2016 (great boat!). I believe these boats were made with closed cell foam core vs.end grain balsa. I'm planning on making substantial changes to the cabin top hardware.. Is the cabin top cored? Are there any solid areas? And what's considered best practice these days: bedding with butyl tape or overdrilling/filling/redrilling? Thanks for any info.

I own Ensign Classic #2016 (great boat!). I believe these boats were made with closed cell foam core vs.end grain balsa. I'm planning on making substantial changes to the cabin top hardware.. Is the cabin top cored? Are there any solid areas? And what's considered best practice these days: bedding with butyl tape or overdrilling/filling/redrilling? Thanks for any info.

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