Bunk recarpet

T

thataway

Active member
After a few years in the Florida sun the bunks need to be recarpeted.
This is the Caracal trailer (an 18 Center Console foot Cat), and although much of the old carpet was OK--wood was showing thru at the very end, there was some corrosion on the mounts, and some wood deterioration.


We used an air driven impact wrench to remove the 1 1/2" x 3/8" lag bolts which held the wood to all of the bunk supports. The same wrench was used to re-install the bolts, and hand tightened with a hand wrench.

We found some corrosion on the aluminum angle brackets on the bottom bunk boards. Those were cleaned up with a power wire brush in a 4" grinder. After these were cleaned up, washed and dried, they were filled with West Systems Epoxy thickened with Cabosil. The side bunks are galvanized. Those pads were rusted; they were wire brushed, treated with "Naval Jelly", primed and then sprayed with liquid galvanizing paint. We launch in brackish water, and wash the trailer after each launch. The prior owner launched in salt water, and we suspect did not wash the trailer.
side_guides.jpg

After the boards were cleaned, any defects were filled with epoxy thickened with Cabisil. The bolt holes were , were also filled with a small amount of thickened epoxy. The new carpet (from Lowes--outdoor polypropylene ) was installed with Monel Staples.
Staples.jpg

We used 3/8 to 9/16" length staples, the longest in the ends. Care is taken to make sure that there are no staples where they could scratch the boat at the ends. The lower end is doubled under the upper to give extra padding at the end of the bunk board.

end_of_bunk_boards.jpg

The side bunks and forward bow bunk are wrapped completely around the board, and the outside layer is oriented away form the hull on the bottom:

bow_bunk.jpg

The bottom of the lower bunk is left bare of carpet in the center to allow drainage.

underside_of_main_bunks.jpg

Finally the finished bunks.

new_carpet_on_Caracal_trailer.jpg
 
Nice photo essay!

I'm curious where you got your Monel staples. I looked/called seemingly everywhere (in Florida yet!) and couldn't find them. Trailer places, no. W.W. Grainger, no. Hardware store... no. Home Depot had them on their website but then in the stores they only carried stainless. West Marine showed them on their website, and I tried calling a couple of their local stores to see if they would check their shelves, but they were too busy at the time -- and they were a long, trafficky drive away -- so I never determined whether or not they had them.

I finally ended up ordering them from Amazon (Arrow brand) and installing the bunk carpet with them another day, but it would (have been) nice to know of a "real store" source, if you found one.

Sure could have used that electric stapler!

Sunbeam
 
Nice job, i would love to have carpet instead of slick bunks. The slick bunks make it difficult to keep the boat centered. Problem is the boat is either in the water or on the trailer.
 
Monel staples are to be found at West Marine (at times). I have also found them at Lowes and Home Depot--but not this time. So, I pick them up when I see them. I also use SS as first "holding" staples, and then go down and do the final tack with Monel metal.

I also have bunks on my lift and they get a lot more immersion than the trailers, and the monel lasts many years. there is no abrasion on the lift bunks, and there is usually a boat on them, so less U V exposure.

Thanks for the kind words.
 
A project well done and documented Bob. I prefer carpeted bunks to slick ones as well - they offer enough friction that you can drive up them(or power load) and the boat won't slide back while you go forward to clip the winch to the bow eye.

Regards, Rob
 
Had no idea monel was so hard to find. They were there at the first place I looked, our local "Co-op Hardware" here in Sequim. I can help if anybody needs.

Harvey
SleepyC:moon

January_2010_181.thumb.jpg
 
:roll:

When it was time to recarpet I chose to go with Azek deck material . It is an all weather all plastic for decks in the wet Northwest. Available at lumber yards, ect. Therefore no carpet for me, but I did put over pressure treated 2x6
 
I looked up Azek deck material. This seems to be a rigid PVC. I am not familiar with this material. Is it soft and protect the hull?

One point I should have brought up, is that I was suspicious that the bunks on the Caracal trailer were treated with copper containing preservatives. Copper interacts with the aluminum and causes corrosion. I have used gasket material in the past to isolate these materials. This time I feel that some of the copper has leached out--and that the thickened epoxy coating would prevent further corrosion. Some salt water treated wood still use copper salts. The common lumber yard pressure treated lumber probably does not, but you should check this when buying new wood for bunks and if you put it next to aluminum. CCA is still used in some applications, especially if you use Salt water treated lumber.
 
Since w're talking bunks:

I would guess it's not available in many (most?) places, but I used cypress when I replaced the bunks on my trailer (in Florida). Apparently it's a "traditional" bunk wood. It sure smelled good in my car :) and it was a pleasure to work.

Sunbeam :hot
 
The Azek deck material does not seem to damage fiberglas. It is smooth on one size and textured on the other and I use smooth side up.

It actually is rather flexible and needs support stringers at 16" on center for decks. I understand that it made from milk cartons and other plastics and resists mould and moss very well.

I have used it on decks for about 3 years and have a underwater boat launch which is holding up very well. :smile
 
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