I just bought a 2009 Stratos 1760DV with a 24v trolling motor. I want to add a 2 bank battery charger to the boat, but, having always owned aluminum, I am afraid of cracking the “glass”. Do I need to start with very small pilot holes and gradually make them bigger?
Thanks!
When I installed mine I just drilled a pilot hole and screwed it in but try to do it whe its warm it will eliminate any possibility of cracking.
Drill whatever size pilot hole you need to give the screw that you are going to be using the proper anchoring strength. There is no need to drill a tiny hole and gradually progress from there. For example I normally use a 1/8 inch drill bit for pretty much all my screw applications. The pilot hole size depends on the size of screw you are going to use. 
Use a sharp new bit. Masking tape the area you are going to drill. Start the hole off by turning the drill bit in reverse for about 15 seconds, then drill the hole slowly. Not too much pressure, let the bit do the work. Use marine sealant on the screw.
-J.
You want to use a counter-sink bit after you drill your pilot hole. This reems the gelcoat out a little bit so a crack doesn’t start.
Quote:
Use a sharp new bit. Masking tape the area you are going to drill. Start the hole off by turning the drill bit in reverse for about 15 seconds, then drill the hole slowly. Not too much pressure, let the bit do the work. Use marine sealant on the screw.
-J.
Excellent way Jon 
U beat me to it
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