H20 Front Cross beam inner bolt renewal

I have been sailing a H16 for 1.5 years now and spent a day with a friend on his Miracle 20. Wow, had to have one! Found what seemed to be a rocking good deal on a 1999 H20, complete, decent sails, beautiful trailer, good hulls, nice price. Further inspection revealed the front beam had both outer bolts removed, one inner bolt drilled all the way out and the other inner bolt broken below the surface of the beam. I bought a new beam, used a cutting wheel to remove the top face of the beam at the broken bolt, chiseled the aluminum compression tube off the broken bolt, and removed the cross beam. Of course the broken bolt sheared down at the fiberglass in the mounting boss. Now I need to drill out the remaining stub of bolt. Annoying but not that hard. I am readying the new beam for installation. The two outer bolt holes still look to have usable threads on the glassed-in aluminum plates. The one already drilled out is a sloppy, oversize mess. The one I still have to drill out is likely to end up the same. Now to my question: The inner bolts seem to end right at the bulkhead under the front beam. Can I trim out the inner corners of the bulkheads so I can use longer bolts, washers and nuts to make the inner fastenings for the crossbeam? The aluminum plate appears to be well glassed in so I feel confident I can thru-bolt onto them, will trimming the inner corners of the bulkheads for access kill the integrity of the structure there?
I scoured the message boards and haven't found the answer to this already so thanks in advance for tolerating this loooong post:)
Thanks,
JayShu
Ocean Springs, MS
H16 88302
H17
H20

How about drilling and tapping the aluminum plate for a helicoil?

sm

Seems like a good solution. There is very little glass below the block if any to hold it in place I'd bet. Making some room for a washer and lock nut would be as secure or better than original.

_________________
Matt Miller
Former - Director of Parts and Accessory Sales
Warranty and Technical Support
Hobie Cat USA
(Retired 11/7/2022)