I ended up cleaning out all the loose stuff from the hull/deck joint, taping it above and below to minimize the mess, and putting in a solid bead of Boat Life caulk. Then fingering it to make sure it was pushed into all voids. Peel the tape off after about 1/2 hour. The danger is that many of the screws are 1" and many are 1.5". The originals are #8 and I went to #10, which doesn't present the head unacceptably proud of the stainless rail. YOU wouldn't notice it. If you try 1.5", screw slowly and set your drill to let go early. I had 2 of the 1.5" STOP at 1.2" and it was hell to get them out. They must've cut into aluminum or something. I snapped the head of one off. So did someone at the factory when the boat came off the production line. I didn't notice it until I was taking everything apart. If you bottom out a 1.5" screw, just back them out of the caulk slowly if they're not going to go, and put in a 1" screw. All seemed to take very well, and the polysulfide makes a pretty good substrate. I think thickened epoxy would add too much work, too much picking and grinding touch up, and you STILL wouldn't know if you needed 1" or 1.5" screws and I doubt it would help much. The stainless rail went back in just fine, all screws bound up acceptably when seated.
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