I may be wrong here, but how strong dose this area need to be? The sun pad goes above this and since it is a large flat area it should diperse any weight over the whole area evenly. How 'bout it all you rocket scientitst out there. Am I wrong here?

Expensive "CUSTOM" headers should fit, or be redone, period.

Couldn't you just put a plug in that bung that is located under the lip and have another bung welded in either 1-2" in front or behind the lip?

If you go the route of the stainless strap, I would put it on the exposed side of the lip. and polish the snot out of it. I love the look of all that shinny stuff.

Cord,

I have had to cut a little into the lip of my deck too because of the water bungs on the headers. I also had to turn a couple of the bungs 90* down instead of having them go straight back(cutting off and rewelding)---it takes time and it's A LOT of horsin' around, but I definately know what you're going through.

if you end up using them as is and cutting the lip i would think something like this would look best...made out of 3/16" or 1/4" stainless with some nice stainless allen heads for thru bolts could even take the back of the box to the transom with a screw or 2 for added support.........I'm pretty bored down here now that my boat is finished so let me know if you want I'll make it / them for you I've got plenty of stainless and alum just waiting to be made into something..

although i still feel it is BS you are going thru this....

Does it have to be metal?
 

For reinforcing the lip -- why not just cut it like you need and use layers of fiberglass to beef up the backside?

Tim, I have to agree with Okie Dokie here. I'd be making a stink if they won't fix their error.

The only problem with having anything done custom is the person doing the fab work needs ALL the peramiters. Was fitting under this lip pre specified? I know I have had custom items made that didn't quite work because I assumeed the fab guy understood what I was saying.

Cord do me a favor. Email me the pictures you have so I can look at them for ya. I will also resize and attach them larger then you have so that everyone can hopefully get a better idea. It is VERY hard to see what is up with the pictures you posted they are to small.

Jon