I ended up using rivets to reseal the cap to hull. Thanks 3rd day. I had never used rivets before. Opened up the seam, cleaned the joint with a knife, resealed with 5200. Pulled the joint together with screws as Michael suggested then installed ss rivets at about a 3" spacing w/ washers on backside.
Couple of lessons learned for me. I'm sure the rest of you know this already.
1. If you dont have two persons installing rivets with one holding washer in place on back, the washer slides off when riveting. I taped in place until I could talk the 10 yr old to hold the washer in place with a screw driver.
2. At the factory some of the rub rail screws were installed over the top of/interfering with the cap/hull screws. There were four instances of this. When the rail is removed the screws break off because they are intermeshed with threads of the hull/cap screws. Rectifying these 4 locations exceeded the duration of the entire rest of the project. A royal pain.
3. My seafari (dont know if the eariler versions do) has a teak strip covering the original hull/cap screws. They had cut the screws off so the teak sits flush. I had to buy a dremel with a little cut-off wheel to cut off the end of the rivets to get the teak strip to seat reasonably.
4. Dont let the alum rub rail hang as you take it off, I bent it a bit right at the bow. Now my boat looks like its snarling when looking at it head on. Nice, dummy.
