Cleaning up the exposed Royalex edge:
I'd also be curious if anyone has secrets for finishing the exposed Royalex edge. It looks porous and dirty and just sort of bugs me. I also have tear-out in many places where the old gunwales had been screwed into place before. Those voids will be visible.
I've considered plunge routing a narrow dado slot to receive a filler piece of wood that I could epoxy into place but that seems like a lot of trouble and a recipe for permanently gluing the gunwales to the hull, making . I also don't relish trimming the top of the hull any lower and losing freeboard.
As ghastly as it might sound, I've considered Bondo too. It's color isn't so dissimilar to the Fir, so maybe it wouldn't be so bad? Not sure how it'll look with tongue oil applied.
Maybe a teak boat deck caulking can that can sanded? A clean black stripe in the middle might look crisp.
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