11. Mount Wedge Pack

Mount Wedge Pack Introduction

Care must be taken to ensure clean working conditions. Wearing clean gloves is highly recommended to keep caustic substances off skin and prevent oil and grease from getting on adhesive surfaces.

11.1. Prepare Parts and Hull

  1. Wipe the area to be bonded with acetone or denatured alcohol and plain white paper towels.
  2. Replace the tape around the border of the abraded portion of the transom where the Transom Plate will be mounted. Mask around the mounting location as well as the bottom of the boat. The tape will help keep the surrounding gelcoat clean of adhesive. The inside of the Cable Gland should be covered to avoid adhesive from entering the gland, particularly when installing with a Concealed Cable Entry as indicated in Section 10.1.
Figure 46 – Tape Masking off Gel Coat
  1. Tape the top and side edges of the Wedge Pack Assembly. Note: The drain holes on the Wedge Pack Assembly, circled in Figure 44 must be covered with tape to avoid adhesive clogging them.
Figure 47 – Drain Hole in Wedge Pack
  1. Wipe the Wedge Pack down with acetone or denatured alcohol using plain white paper towels to remove oil/surface contaminates.

11.2. Sand Adhered Surface

  1. Using 60 grit sandpaper, scuff the entire back and bottom of the Transom Plate by hand. You may use a Dual Action Sander (DA), but you must be extremely careful not to remove excess material. DO NOT use a grinder or heavy abrasive for this process. The mounting surface of the Transom Plate should have a matte gray finish when properly prepared with sandpaper. Note: Be careful not to sand down the standoff bumps on the plate circled in blue below.
Figure 48 – Sanding Transom Plate
Figure 49 – Standoff Bumps (Circled in Blue) Are Not to Be Sanded

11.3. Clean Adhered Surfaces

  1. Wipe the Wedge Pack down with acetone or denatured alcohol and plain white paper towels a second time to remove oil and/or surface contaminates after sanding.
  2. Clean the transom mounting location with acetone or denatured alcohol and plain white paper towels a second time to remove oil and/or surface contaminates after sanding.

11.4. Mount Wedge Pack

  1. Apply a generous layer of adhesive to both the Transom Plate and transom as shown below The Transom Plate has three (3) stand offs to allow for adequate adhesive thickness once mounted. Note: Work from this point on should be deliberate, keeping in mind the working time of the adhesive being applied. Warmer temperatures reduce working time.
Figure 50 – Adhesive on Wedge Pack and Transom
  1. Install the Wedge Pack Assembly by sliding the keyholes over the positioning screws. Excess adhesive should appear around the entire perimeter of the Wedge Pack Assembly as the Wedge Pack is pressed into place.

11.5. Confirm Location

  1. Add the Seal Plate to the assembly to check its position as indicated in Section 9. Insert the six (6) M6-1.0 x 30 mm bolts and washers to hold the Seal Plate, as shown below. (600 mm Controllers will have eight [8] bolts and washers.) Note: Apply thread locking sealant, but do not apply the final torque during this step.
Figure 51 – Seal Plate Temporary Installation
  1. Using a straight edge, verify the Wedge Pack is parallel with the hull bottom in the desired location as determined in Section 5. Due to different hull shapes and features, the Seal Plate may not be parallel to the hull bottom across its full span.
Figure 52 – Seal Plate Alignment Confirmation
  1. Once the position is confirmed, remove the Seal Plate, and tighten the positioning screws with a Phillips head screwdriver. The screws must be tight enough to press out excess adhesive and keep the assembly from sagging, but do not overtighten or the transom plate may crack.

Note: In the uncommon case that the measured transom angles for the inboard and outboard sides of a Controller location (found in Section 6.1) are greater than 2 degrees apart, tighten beginning on the side with the larger transom angle pulling it tight to the transom. On the side with the smaller transom angle, gently advance the screws but do not tighten it all the way to the transom. If the screws on the side of the smaller transom angle are overtightened, the Wedge Pack will warp and cause issues. Be sure there is enough methacrylate adhesive between the Transom Plate and the transom for a strong bond with no voids.

11.6. Fair in Excess Glue

  1. Using a squeegee, putty knife, or tongue depressor, fill in the gap between the running surface of the hull and the Actuator Plate with excess adhesive, as shown below. Apply extra adhesive as needed.
Figure 53 – Adhesive Filling Between Hull Bottom and Actuator Plate
  1. The smooth transition from the hull bottom to the Seal Plate is critical for achieving the best performance out of the system.
  2. Using a squeegee, putty knife, or tongue depressor, clean away excess adhesive.
  3. Fillet excess adhesive on the upper edges of the Transom Plate to the transom. Apply extra adhesive as needed.
  4. Remove the masking tape from the Wedge Pack Assembly and transom. If needed, clean any excess adhesive using acetone or denatured alcohol and plain white paper towels.
  5. Allow resin to cure before proceeding. Some adhesives have ‘handling times’ where the product feels firm but is not ready for loading. Some adhesives also have required times before submersion. Please follow the adhesive manufacturer’s instructions.
  6. After fairing, check that the drain hole has remained clear. See Figure 47.