[C320-list] May track installation

[Jeff]

Daryl,

I'll check tomorrow on the screws I used.  But here are some things you might want to keep in mind.  

1. Use a forming tap, not a cutting tap. Forming taps mould the metal into threads as they are threaded in. The process is quite easy. You'll end up with better, stronger threads and fewer metal shavings inside the mast to clog the drain hole. I got a package of 5 on eBay for something like 15 bucks.  One of them lasted the whole job. I could send you one if needed.
2. Dip your drill bit and forming tap in "Alumet" cutting solution after every 3 or 4 holes.  Doesn't take much but makes a big difference in the hole quality. One simple dip is all you need to protect the drill bit!  It's magic.  I was able to get a local machine shop to give me a couple tablespoons of it for this job.
3. I Put some double stick tape on the back of the track and use 3 or 4 clamps to hold it in position.
4. Put a wrap of tape around the drill bit so you know how deep to drill and protect the anodizing on the t track during drilling.
5. Do not drill all the holes at once!!  Start at the top, drill, tap, then put the screw in. Then move on to the next one.  If you drill multiple holes, or skip holes, you may find that the holes seem to creep it of alignment or worse, the track may expand in the sun differently than the mast so go in order and save yourself the headaches!
6. Loctite isn't necessary but instead, coat the threads with Tef-Gel anti-seizing grease.  The screws won't back out, don't worry.
7. Buy a short chunk of flat aluminum stock from Home Depot and try a couple test holes to be sure you have the best drill bit size and get comfortable with the process. Forming taps require a slightly different diameter bit than cutting taps.
8. Make sure to mount the end of the track high enough off the deck that you can get the cars on and off the bottom or you'll end up needing a ladder to get them off the top of the track.
9. I used T track end stops at the top and bottom of the track.

Not a hard job but a second person is pretty much essential.

Jeff Hare
#809

Sent from my iPad

> On Jul 2, 2016, at 3:30 PM, Daryl Hunt <drhunt at rochester.rr.com> wrote:
> 
> 
> 
> Installing a whisker pole track on my mast.  About to drill and tap holes for the 1/4" x 5/8" SS screws when it occurred to me that I might want to use the finer 24 vs 20 threads/inch screws since I've only got about .125" of mast thickness to hold them.   Of course, I also plan to use lock-tite blue for extra grip and to inhibit galvanic corrosion.   Any thoughts on the screw selection?
> regards, Daryl C320 #660 BelieveRochester, NY