Boy, I think I'd just stick with your current expando plug in the DePersia. The Elvstrom needs a fair-sized hole in a pretty flat part of the hull that's also out of the way, but still convenient to reach--bit of a PITA all the way around in the small Sunfish cockpit. If used a lot the gaskets...
Elvstrom-style bailers work pretty well (better, I think, then the plastic Sunfish bailers), but can be a pain to step on with bare feet. If the boat is slid over beach/grass/dock/trailer bunk/whatever they're prone to damage if not securely closed.
"Old Style" plastic bailer - pre 1973
Part# 91025 (complete) - thread cap is 1-5/16" deep
"New Style" plastic bailer - post 1973
Part# 91026 (complete) - thread cap is 1-3/16" deep
Replacement bailer balls
Part# 91031 (for 5 pack) - balls are 5/8" diameter
To expand on what beldar boathead suggests:
Remember that when aluminum is crimped like this the aluminum work-hardens in the area of the crimp, and that area becomes more brittle than the rest of the spar. I would not try to remove the crimp or straighten this spar (= more bending & more...
Tri-grip pop rivets don't need backing washers, & have quite good tensile strength. See typical shear/tensile specs here:
There is lots of choice in head profile, shank diameter, & grip range (length). Many NASCAR...
Fill the old hole with your choice of polyester/epoxy goop, then redrill and fasten with tri-grip pop rivets. These rivets resist pullout well & install with a regular pop rivet tool:
This is a pic (I believe) of Wavedancer's older Trailex SUT-200-S, the one with the crummy rubber molding suspension. It would be quite easy to retrofit this trailer with a transverse leaf suspension:
• remove the aluminum risers at the ends of the axle (marked with red "Xs").
• through-bolt the...