When the 1983 to 1986 Hunters were assembled the cowl vents were an unusual size. The diameter was 5.75 and the company that manufactured them were located in San Diego, California. Well, they no longer exist. There is a company that makes replacements but they area a few more pennies than I want to spend.

Original Cowl Vents

After removing the vents and the flange I cleaned the entire deck they set on with acetone and lightly sanded that same area. The plywood core was exposed so I used West System to cover it and the small holes that secured the flange to the deck.

Take them out

Using a chisel and a rubber mallet heres whats left of the original deck flanges.

Whats left

I particularly like the look of mahogany, (see my cabinet project) so back to my local wood store to buy some more. What I used was 1/2 by 7 by 24 board. A small router table rounded the edges and I placed it over the deck to draw the holes using the new cowl flange as a templet. The new cowl is a 4 3/4 OD, using a drill to make the hole for the jig-saw and away we go.

Mahogany instead of Teak

After cutting the new flange holes I used 2x 1/4 ss bolts with a washer, lock washer and nut on the four corners. In the middle I used self tapping screws to keep the entire plate flat to the deck (along with good ole 4200 around the edges).

Secure the new plate

Took only 2 hours and finished with Sikkens Cetol. The Cowl Vents were purchase at West Marine for only $45.00, total cost of the project was just under $100.00. Really makes for a nice look.

Done