Cutout for Raymarine ST 60

[clifford Rieders]

Okey, here is an obvious question (for anyone who has done it). Thanks to suggstions here, I replaced the ST 50 with ST 60 instruments which have a 3 1/2 inche cutout. What is the quickest tool for enlarging the cutout in the old (thick fiberglass) Edson pod? Any other install hints? Thanks

[Ron Hill]

Cliff : I'd try a plunge router to make that small enlargement.   To discourage chipping move the router counter clockwise.   

[rirvine]

Here is how I did the exact some project:

A. Cut a piece of wood (redwood works well as it is soft) to fit snug inside the faceplate of the Edson Pod and about 8" long.

B. Clamps the wood inside the faceplate covering the existing hole to be enlarged.

C. Place a hole drill of the same size as the existing hole in a drill press with the pilot removed.

D. Align the hole to be enlarged with the hole drill in the drill press. This put the hole drill's pilot at the center of the existing hole. 

E. Clamp the faceplate and wood to the drill press.  There is some experimenting to get all the clamps in the right places so it can be clamped to the drill press.

F. Replace the hole drill with a 3.5" hole drill – with the pilot fully extended - in the drill press.  This allows the pilot to drill well into the wood before the hole drill comes in contact with the faceplate.

G. Slow drill the new hole.

The important items are a supply of good clamps of various sizes, two hole drills, and a drill press.  You will find it extremely difficult to be successful without the drill press

[BillG]

I just built a holder for my Raymarine autopilot control out of teak but the process is the same.  I started by making a template out of 1/4 inch masonite with a 3 1/2 inch hole.   That can be fastened to the front (hot glue works well) and then use a router with a flush cutting bit to make the hole.  Simple!

[clifford Rieders]

I really appreciate the advice. I have the 3 1/3 hole bit but I did not think of the rest and hope I can do it without buying the smaller size too since they are about 18-20 bucks. The idea of using the press never crossed my mind. Did you fit the old cables to the new (rebuilt) instruments? Thanks again

[rirvine]

I used the short Seatalk cables that come with the ST60 instruments to join the ST60 instruments together.   For the tranducers, I cut the connector off and joined them to the new instruments - all worked first time.

Good luck, Ray